Download Owner`s Manual

Owner’s Manual
Marine Diesel Engines
HPE Series
HPE 40S/80/80SD/110/110JD
HPE/P 40/150/150JD/170/170JD/190/190JD
HPE/P 100/225/225JD/250/250JD/250H
HPE/P 300
HPEL 45/80/65/90
Table of contents
1
General information
1.1
1.2
1.3
1.4
1.5
1.6
1.7
2
Using the FNM® engine, HPE series
2.1
2.2
2.3
2.4
2.5
2.6
3
About this manual
Guidance on identification of important information
Notes on FNM® engines servicing
Identification of your engine
General safety regulations
Main components of FNM® engine, HPE Series
Engine delivery
Analog Instrument Panel
Digital Instrument Panel
First engine starting and sea trial
Engine starting and stopping operations
Throttle
Notes on daily use of the engine
Maintenance of FNM® engines, HPE Series
3.1
3.2
3.3
General information on maintenance
Periodic organization and frequency of maintenance operations
Details of maintenance operations
FNM® HPE Series
3
5
6
7
9
11
15
22
23
24
27
38
41
49
58
60
61
64
68
1
3.4
3.5
3.6
3.7
4
Maintenance booklet
4.1
4.2
2
Engine treatment and maintenance products
Periods of engine inactivity
Other useful information for maintenance
Specifications of your engine
98
101
106
108
129
Engine Identification Data | Dati identificativi del motore
130
Ordinary and Extraordinary Maintenance Register | Registro della manutenzione periodica programmata e
straordinaria
131
FNM® HPE Series
1 General information
FNM® HPE Series
3
Dear customer
Fratelli Negri Motori (hereinafter FNM ) is pleased to thank you for choosing an engine of HPE range.
FNM® engines are designed and developed according to the demand and the needs of customers and builders of
pleasure and work boats.
CMD S.p.A., the company that produces and distributes worldwide the marine diesel engines with the FNM® brand,
offers a wide range of products and models according to each customer's request.
FNM engines ® are known around the world:
-
for their performances;
-
for their compact structure and outstanding power-to-weight ratio;
-
for their long life and low fuel consumption.
This means that, when buying an FNM® engine, you have chosen not only a technologically advanced engine, but
also an engine designed to satisfy the anti-pollution standards and regulations.
Mariano Negri
CEO of CMD S.p.A.
4
Giorgio Negri
Sales Manager of FNM® brand
FNM® HPE Series
1.1 About this manual
This manual is integral part of the engine and is written by the manufacturer to inform the end user of
the procedures necessary for the proper use and maintenance of marine diesel engine FNM, HPE
Series.
Please keep this manual for the entire life of the product so that you always get quick information on
the engine during use.
The manufacturer reserves the right to modify this document without prior notice.
The observance of the installation procedures and routine maintenance in this manual and in the
installation manual ensures compliance at the declared performance at the and gas exhaust emission
and noise parameters for which your engine is approved in accordance with the Directives 2003/44/EC
and EPA/TIER/3.
This manual provides important information on maintenance, operations to be carried out periodically
and handling of your engine.
Before starting your engine, we advise you to read this manual in order to get the information
necessary to operate your engine.
The proper use of the FNM® engine, as well as proper maintenance plan during the period of activity
and inactivity of the engine, ensures its durability and performance.
FNM® HPE Series
5
1.2 Guidance on identification of important information
In the manual you will find a color guide that indicates the degree of importance of information for use
or maintenance of your FNM® engine.
There are three levels of importance:
Danger icon: dangerous situations that may compromise the safety of persons and
engine functionality.
Beware icon: indicates the need to follow the instructions as presented in this manual,
otherwise the engine functionality can be reduced.
Informations: indicates important technical information.
To these are added the environmental information, as indicated below:
Respect the environment, do throw away pollutants
The important information is shown in the rest of this manual with the color for one of these levels, as
shown above.
6
FNM® HPE Series
1.3 Notes on FNM® engines servicing
For your engine service and maintenance always refer to an authorized service centers and to
the FNM® service network. Only by using original spare parts and relying on our specialized staff you
can get the best performances from the engine and ensure a long life.
The FNM® service centers offer low costs and a high degree of specialization. Our service centers
ensure the correct operation of the engine according to all your expectations. Visit our website
www.fnm-marine.com to know the nearest service point.
The reliability of the total propulsion unit is dependent on the quality of the installation. Nearly all the
problems are caused by faults or inaccuracies which occur during the installation. FNM® is not
responsible for damages (engine and/or persons) caused by wrong installation.
Ask your installer the effective compliance of the installation of your engine, as well as a copy of the
installation form, necessary so as the warranty is held invalid for the FNM® service.
If the installer does not transmit the installation form to FNM® this may invalidate the warranty.
To get help on your engine and for warranty information, please feel free to contact FNM® at
[email protected].
FNM® HPE Series
7
1.3.1 Spare Parts
The exclusive use of FNM® original spare parts is an essential condition for a good maintenance of the
engine. The use of non-original spare parts may cause the warranty to expire and it also exempts the
company CMD S.p.A (owner of the FNM® brand name and logo) from any responsibility.
1.3.2 Responsibility
The responsibility of the Manufacturer is subject to the correct execution of the “Maintenance Procedures” operations that are described in this manual. For this purpose, it will be necessary to
demonstrate that all the maintenance procedures and operations have been carried out according to
the manual and that, in case of extraordinary maintenance, the procedures and operations have been
carried out by FNM® Service centers.
The information featured in this manual only refer to the engine itself; more specifically, the illustrations
serve as a pure indication and the instructions are described in a purely functional way with the
purpose of providing help and guidance in carrying out the ordinary maintenance. The execution of
such operations may vary based on the configuration of the controls and/or accessories of the boat
where the engine has been installed. The information featured in this manual is correct at the time of
printing. The Engine Manufacturer reserves the right to make modifications without notice at any time
for technical or commercial reasons as well as for the need to abide by new regulations or norms. The
Engine Manufacturer declines any responsibility that may arise from possible mistakes and/or
omissions during the installation.
It is forbidden to alter the characteristics of the engine and in particular the configuration of the control
unit (or ECU box) because such modifications and/or alterations will invalid the warranty and safety
terms.
8
FNM® HPE Series
1.4 Identification of your engine
The ID label is applied on your engine and on the control unit (or ECU box) in the position indicated in
the table below (see also paragraph Main components of FNM® engine, HPE Series on page 15):
Engine
HPE 40S/80/80SD/110/110JD
HPE/P 40/150/150JD/170/170JD/190/190JD
HPE/P 100/225/225JD/250/250JD/250H
HPE/P 300
HPEL 45
HPEL 80
HPEL 65/90
Label location
On the engine cover.
On top of the engine, attached to the
intercooler housing.
On the cooled exhaust manifold on the right
side of the engine.
On the engine cover.
The data on the ID label will include:
-
FNM® HPE Series
Engine Type
Engine Family
Serial No.
Year of manufacture
Test speed (Rpm)
Power in kW (kW)
Horsepower (HP)
Costruzioni Motori Diesel SpA
Z.I. Valle di Vitalba
85020 Atella (PZ) Italy
Engine Type: HPE110
Engine Family: 13T4L550
Serial N°: 47110XX Year: 2011
Rpm: 4400 kW: 80.88 HP:110
9
The engine serial number is also printed on the engine block. The position is indicated in the table
below (see also paragraph Main components of FNM® engine, HPE Series on page 15):
Engine
HPE 40S/80/80SD/110/110JD
HPE/P 40/150/150JD/170/170JD/190/190JD
HPE/P 100/225/225JD/250/250JD/250H
HPE/P 300
HPEL 45
HPEL 80
HPEL 65/90
10
Engine serial number position
On the crankcase, right side, bell housing connection.
On the crankcase, front side, above the bell housing.
On the crankcase, right side, bell housing connection.
FNM® HPE Series
1.5 General safety regulations
Read carefully the information contained in this chapter in order to avoid unpleasant incidents.
The manufacturer cannot be held responsible for any damage resulting from misuse of the engine,
from the failure to follow the indications contained in this manual and for every tampering with or
change made without the manufacturer’s authorization.
Do not drive the boat if you consume alcohol or other substances that may alter your
state of attention and reflexes.
-
Use the engine only for the tasks authorized by the manufacturer, do not tamper any device to
obtain different performances.
-
Consult only technical staff, with experience and specific technical skills. The lack of these
requirements could result in damage to people’s safety as well as damage to the engine.
-
Pay attention to the meaning of the symbols and the labels applied. Keep them visible and
follow the warnings indicated.
-
Carry out the engine handling in accordance with the information provided directly on the
engine and on the packaging. During the engine lifting and transportation, use means with
appropriate load capacity.
-
During the installation the installer shall follow the manufacturer’s instructions. Do not make changes to the engine components for any reason!
FNM® HPE Series
11
12
-
Before using the engine for the first time simulate a few trial maneuvers to identify the controls
and their main functions, especially those related to start -stop operations. Do not keep using
the engine if anomalies are detected.
-
In case of anomaly, stop immediately the engine or reduce the speed as far as possible. Start
again only when the normal operating conditions are restored.
-
Keep the engine and related components in conditions of maximum efficiency and carry out the
maintenance operations established by the manufacturer and repeated in this manual.
-
Replace only original spare parts. Use only oil, lubricants and grease recommended by the
manufacturer in accordance with the specifications of this manual.
-
Pay attention to the disposal of polluting residues (used oil, diesel fuel, etc.) following the local
legislation and disposal procedures.
-
Do not unscrew the expansion tank cap of the cooling system when the engine is hot! Slowly
turn until any steam under pressure comes out, and then remove the cap.
-
Do not start the engine without the air filter: the detachment of rotor parts of the compressor
during operation could cause damage to persons, furthermore any aspirated particles could
damage the blades. Avoid contact of hands with the rotor.
-
Do not touch the turbocharger and the turbine cover with hands immediately after using the
engine, risk of burns. Let engine cool before interacting with the hot parts.
FNM® HPE Series
-
Do not smoke near the battery compartment and the fuel tank! The battery can release
flammable gases. Wrong battery connection could provoke sparks and explosion.
-
Don’t provoke short circuits, electrical risk.
-
If you use pressure water jet to clean the engine never point this to rubber pipes or electrical
connections.
-
Use proper protection (clothing, gloves, etc.) during maintenance and/or work on the engine.
-
During maintenance operations provide correct ventilation. Avoid stagnation of toxic and/or
flammable vapors.
-
Do not remove the protections included in your engine (such as housing or protective coatings),
to avoid danger of fires.
1.5.1 Residual risks
Potential/additional risks to persons:
Risk of injury: do not put hands in any moving parts (pulleys, flywheel, belts, etc.).
Risk of burns: attention to hot surfaces (exhaust manifold, turbocharger, raiser, etc.)
FNM® HPE Series
13
Risk of poisoning: watch out for oil splashes, hot fuel and battery acids in case of
malfunction: use gloves and safety glasses.
Risk of shock: use safety shoes when lifting the engine and/or working in the engine
compartment.
FNM ® is not responsible for damage caused by misuse of the engine and the failure to follow
procedures issued, as well as for damage caused by unauthorized personnel.
14
FNM® HPE Series
1.6 Main components of FNM® engine, HPE Series
The main components present on HPE marine engines are listed below.
(1)
Intercooler (except HPEL45): Reduces the temperature of the compressed air from the
compressor that flows into the engine intake duct using a bundle of finned tubes crossed
by sea water.
(2)
Expansion tank: contains engine coolant.
(3)
Oil sump: contains engine lubrication oil.
(4)
Zinc anodes: prevent the galvanic oxidation of metal parts.
(5)
Oil exchanger: reduces the temperature of the engine lubrication oil.
(6)
Diesel fuel exchanger: reduces the temperature of the fuel in the return line to the
exchanger.
(7)
Air filter: retains the impurities in the air intake.
(8)
Dual heat exchanger (as an alternative to diesel fuel exchanger and in the presence
of steering): reduces the temperature of steering oil and diesel fuel.
(9)
Turbocharger (except HPEL45): compresses the intake air exploiting the energy of
exhaust gases through the use of a turbine-compressor group.
(10)
Diesel fuel filter: filters diesel fuel in inlet to the supply line of the engine It can be wallmounted in the engine compartment.
FNM® HPE Series
15
16
(11)
Raiser: reduces the temperature of the exhaust gases coming out of the turbine, conveys
fumes towards the exhaust and prevents the return of sea water into the turbine.
(12)
Starter: starts the engine.
(13)
Water to water exchanger: reduces the temperature of engine coolant through heat
exchange with sea water.
(14)
Low-pressure electric fuel pump: sucks fuel from the low pressure line and sends it to
the high pressure line.
(15)
Thermostat housing: contains the thermostatic valve of the cooling circuit.
(16)
Sea water pump: sucks water from the sea water intake and pushes it in the cooling
circuit.
(17)
Alternator: generates electric power, the output voltage is 12 Volt.
(18)
Oil filler cap: useful in filling the engine oil.
(19)
Lifting eyes: allow the movement of the engine outside the engine compartment.
(20)
Engine label position
(21)
Serial number position on the crankcase
(22)
Oil drain valve
FNM® HPE Series
18
19
20
7
2
9
13
19
4
11
21
1
5
16
17
10
6
15
14
12
3
Figure 1 – FNM® HPE 40S/80/80SD/110/110JD – FNM® HPEL 80
FNM® HPE Series
17
19
20
7
2
9
1
18
11
19
22
16
8
21
10
13
17
12
15
14
3
Figura 2 – FNM® HPE/P 40/150/150JD/170/170JD/190/190JD – FNM® HPEL 65/90
18
FNM® HPE Series
7
1
2
9
20
19
18
11
19
22
16
8
21
10
13
17
12
15
14
3
Figura 3 – FNM® HPE/P 100/225/225JD/250/250JD/250H
FNM® HPE Series
19
19
18
10
14
1
19
16
20
2
7
13
19
21
9
17
8
13
12
22
11
15
3
Figure 4 – FNM® HPE/P 300
20
FNM® HPE Series
20
18
19
2
19
11
13
7
21
5
16
17
15
14
12
3
Figure 5 – FNM® HPEL 45
FNM® HPE Series
21
1.7 Engine delivery
At moment of receiving an HPE engine please check:
-
The integrity of the packaging, if the engine was supplied not installed (the wood box must be
integral, the engine must be fixed on the wood support and secured to it).
-
The ECU box must be integral and with no obvious signs of breakage.
-
The engine wiring and any extensions must be integral with no cuts, the Amphenol® connector
must be integral and all the pins of the connector must be correctly positioned.
-
The instrument panel and connection cable must be integral.
-
Any fluids leaks.
At the time of shipment engines are bench tested and packaged according to internal
specifications. FNM® is not responsible for damages caused by the carrier/transport company.
22
FNM® HPE Series
2 Using the FNM® engine, HPE series
FNM® HPE Series
23
2.1 Analog Instrument Panel
If your FNM® HPE engine is equipped with an analog instrument panel, it can have an instrument
panel complete with key lock, indicators and indicator lights (Figure 7 - Analog instrument panel in
separate configuration on page 26), or only an instrument panel with lock key and indicator lights
(Figure 7 on page PAGEREF _Ref320107452 \h 26) with separate analog instruments, depending on
the type of installation. In both cases, all indicators are also available as an option.
The elements present on the instrument panels are as follows:
24
(1)
Key Lock: allows to start and stop the engine
(2)
Test Button: allows checking the indicator lights operation on the panel.
(3)
Backlight: turns on or off the backlight of the panel.
(4)
Fuse: Protects the panel instruments against overcurrent.
(5)
Coolant high temperature indicator light:
(6)
Oil low pressure indicator light:
(7)
Glows plugs indicator light:
active (at the start-up).
(8)
Alternator indicator light:
lights up when the coolant is too hot.
lights up when the oil pressure is too low.
lights up when the preheating system of the engine is
lights up when the alternator is not charging the battery.
FNM® HPE Series
(9)
Voltmeter: measures the battery voltage in volts.
(10) Engine oil pressure indicator: measures the engine oil pressure in bar or psi.
(11) Crankshaft revolutions counter: measures the engine crankshaft speed rotation in RPM.
(12) Coolant thermometer: measures the engine coolant temperature in °C and °F.
(13) Hourmeter clock: indicates the number of hours that the engine has run.
Each panel has an alarm buzzer that signals the situations of potential danger.
For information on the operating status of indicators and indicator lights on the engine panel refer to
chapter 3.7.2 - Meaning of the indicators on the analog panel on page 112.
FNM® HPE Series
25
11
2
10
3
4
12
4
13
9
1
8
3
8
7
6
5
2
7
6
5
Figure 7 - Analog instrument panel in
separate configuration
1
Figure 6- Complete analog instrument panel
26
FNM® HPE Series
2.2 Digital Instrument Panel
If your FNM® HPE engine is equipped with digital instruments, it can have an instrument panel
complete with key lock, lights and indicators (Figure 8- Complete digital instrument panel on page 29),
or only an instrument panel with lock key and indicators (Figure 9 - Analog instrument panel in
separate configuration on page 29) with separate digital instruments, depending on the type of
installation. In both cases, all indicators are also available as an option.
The elements present on the instrument panels are as follows:
(1) Key Lock: allows to start and stop the engine.
(2) Crankshaft revolutions counter: measures the engine crankshaft speed rotation in RPM.
(3) CANBUS universal instrument: allows to display all the engine operating parameters. The
integrated display allows to view also the alarms related to the engine. Consult the table on page
116 for a list of the situations reported and the management of situations of potential danger.
The instrument also has a buzzer and some warning lights to indicate anomaly situations.
(4) Mode Button:
(5) Direction buttons:
instrument.
To change the operating mode of the CANBUS universal instrument.
and
(6) Glows plugs indicator light:
(at the start-up).
FNM® HPE Series
to scroll through menus and views of the CANBUS universal
lights up when the preheating system of the engine is active
27
(7) Transmission oil anomaly indicator light:
lights up when the transmission has low oil
pressure, or the level of the oil tank is below the minimum.
(8) Other indicator lights: Optionals (depend on boat installation).
28
FNM® HPE Series
6
6
8
7
8
7
1
4
Figure 9 - Analog instrument panel in
separate configuration
3
2
5
1
Figure 8- Complete digital instrument panel
2.2.1 The universal CANBUS instrument
The digital instrument panel features a LCD display and some buttons that make up the CANBUS
universal instrument. The instrument is capable of displaying various information of the engine.
FNM® HPE Series
29
When turned on the instrument performs the self-control mode of check the operation of its electronics.
So it moves to normal mode and for factory settings, it displays the battery voltage (Volts), the engine
coolant temperature (Coolant Tmp) as shown in Figure 10:
VOLTS
13.8 Volts
Coolant Tmp
100° C
Figure 10 - CANBUS universal instrument normal mode
The instrument has three operating modes: Normal, Selection and Setting.
2.2.2 Normal Mode
It is used during normal operation of the instrument. The screen looks like the image in Figure 10,
unless you set the screen of another view as a standard normal mode screen.
In normal mode the pressure of the arrow keys
LCD contrast for better viewing.
30
and
allows you increase or decrease the
FNM® HPE Series
Pressing once the Mode button
Pressing simultaneously the
enter the Setting mode.
allows you to enter the Selection mode.
Mode button and the up arrow button
instead allows you to
In normal mode, when situations of potential danger or engine malfunction occur, an alarm appears on
the display. The appearance of the alarm makes the buzzer ring and turns on the alarm lights, placed
behind the revolution counter.
CHECK
ENGINE
!
Figure 11 - Alarm display example
To disable the warning, turn off the buzzer and the alarm lights and press the Mode button
. The
alarm will recur after 15 minutes if not resolved. Once disabled the alarms they can still be consulted
on the last screen of the Selection mode.
FNM® HPE Series
31
Consult
32
the
possible
alarm
messages
that
may
be
displayed
in
3.7.3
FNM® HPE Series
-
Meaning of the indicators on the digital panel- on page 115.
2.2.3 Selection Mode
The Selection mode allows you to check the parameters that are not normally shown on the
instrument.
From normal mode, pressing once the Mode button
allows you to enter the Selection mode.
Pressing the Mode button
or staying for more than 4 seconds in the Selection mode without
pressing any key makes it return to Normal mode.
In Selection mode, the arrow keys
and
can be used to display alternative screens
containing other parameters monitored by the instrument:
FNM® HPE Series
33
VOLTS
13.8 Volts
Coolant Tmp
100° C
Oil Press
2.76 bar Fuel
Used
10 Ltrs
Trans Gear
2 Forward
Trans Temp
165° C
Trans Press
13.8 bar
Boost Press
0.3 bar
Screen 1 (displayed in
Normal Mode)
Screen 2
Screen 3
Screen 4
Fuel Level


Throttle
33 %
Engine Load
20 %
TRIM


Engine Hour
35 Hrs
Fuel Level


ALARM
SCREEN
WILL DISPLAY
ENGINE and
LOCAL Alarms
When occuring
Screen 5
Screen 6
Screen 7
Screen 8
Figure 10 - Possible displays in Selection mode
34
FNM® HPE Series
In Selection mode pressing the down arrow allows to switch from screen 1 to screen 2, and so on.
Pressing the up arrow allows you to go back. Screen 8 is displayed only if there are errors or warnings
to report.
The information you can see are the following:
(1)
Volts: is the operating voltage of the battery in volts.
(2)
Trim: is the position proportional to the trim inclination angle.
The Trim location information is only available in applications that require the adjustment of the
trim, such as the stern drive.
(3)
Oil Press: is the engine oil pressure in bar or PSI.
(4)
Engine Hour: is the total number of running hours of your marine engine.
(5)
Fuel Level and Fuel Left: it is an indication of the fuel level in the tank.
(6)
Water Press: is the engine coolant pressure.
(7)
Fuel Used: is the amount of fuel used since last reset of the instrument.
Information relating to the fuel (Fuel Level, Fuel Left, Fuel Used) are available only with a
special float for the level measurement. Get information from your installer if it is installed on
your boat.
(8)
Trans Gear: shows the current gear engaged in the transmission.
(9)
Trans Temp: Indicates the current oil temperature in the transmission.
FNM® HPE Series
35
(10) Trans Press: indicates the current oil pressure in the transmission.
Information relating to the transmission (Trans Gear, Trans Temp and Trans Press) are
available only with the sensors properly installed on the transmission. Get information from
your installer they are installed on your boat.
(11) Boost Press: shows the current engine boost pressure (turbocharger boost pressure).
(12) Throttle or Engine Load: show the percentage relative to the position of the throttle.
(13) Coolant Tmp: shows the engine coolant temperature.
For more information about the displayed information and warning views that may appear, see the
paragraph
3.7.3
-
36
FNM® HPE Series
Meaning of the indicators on the digital panel- on page 115.
2.2.4 Setting Mode
The setting mode allows you to set all the parameters of the instrument.
In normal mode pressing simultaneously the Mode button
you to enter the Setting mode.
and the up arrow button
allows
Pressing the Mode button
or staying for more than 40 seconds in the Selection mode without
pressing any key makes it return to Normal mode.
In Setting mode, the arrow keys
and
can be used to display alternative screens containing
other functions that allow you to set the instrument
To enter a function press and hold the arrow keys
and
simultaneously for at least 2 seconds.
Use the same key combination to give a confirmation, and the Mode button
to go back.
The functions which can be modified on the instrument are shown in the figure below. For more
information consult the manual of digital instrument (available also on the website www.fariainstruments.com).
FNM® HPE Series
37
Select
Default
Screen
Reset
Fuel
Used
Set
Fuel Tank
Full
Set
Amount
Of Fuel
Organize
User
Screens
Function 1
Function 2
Function 3
Function 4
Function 5
Select
Gauge
Range
Select
Fuel
Sender
Select
Display
Units
Select
Fuel Tank
Size
Fuel
Tank
Calibrate
Function 6
Function 7
Function 8
Function 9
Function 10
Low
Fuel
Alarm
Select
Self
Test
Software Id
&
Revision
Minigatewa
y
J1939
PGFxxxx
Function 11
Function 12
Function 13
Figure 11 - Possible functions of the Setting Mode
38
FNM® HPE Series
2.3 First engine starting and sea trial
2.3.1 Checks and preliminary operations
Follow the directions before starting the engine for the first time.
It is preferable and highly recommended to follow the directions together with your installer.
1. Check the weather conditions, do not put into the sea if the sea is too rough or bad weather is
forecasted.
2. Make sure you have carefully read this instruction manual. The information contained in it will
be useful in the management of your engine.
3. Check the fuel supply line and the presence of any leaks. Be careful to avoid sharp bends or
kinks along the fuel supply line. Also be sure that the line is clean and free of air bubbles.
4. Verify if you need to lubricate or grease the pinion of the starter and transmission couplings.
5. Check and verify the correct installation of electrical connections.
Wrong connection may cause short circuits and cause damage to persons and to the
engine.
FNM® HPE Series
39
6. Check the battery integrity and the correct state of charge. Turn ON the battery main switch.
7. Check the sea water circuit and verify that the valve is open.
8. Check the belts and tighteners status.
9. Check all the engine oil levels and verify that they are correct, then check the fuel level in the
tank.
10. Turn ON the red button on ECU box and verify that all the LEDs are lighted.
11. Verify the lever command status and that it is in Neutral position.
12. Verify the oil level in the gearbox or in the stern drive.
13. Check the correct propulsion-engine assembly alignment.
Compile the installation form in all parts with the installer and make sure that it is sent it to the
engine manufacturer after the first engine start and boat test in the sea in order to start the
guarantee.
2.3.2 First engine start
To carry out the actual first engine start:
1. Start the engine, turning the key to position I for some seconds (Figure 12 - Situation of the
panel with engine off, key to position I.
40
FNM® HPE Series
2.
on page 42) and then to position II when the light of the glow plugs turn off (Figure 13 - Hold
the key to position II until the engine starts. on page 43).
3. Let the engine warm up for few minutes at minimum RPM.
4. Carry out the engine diagnosis with the installer, so that it acquires the reference data. These
data must be copied into the installation form in order to validate the FNM® engine warranty.
5. Check for any leaks, verify the correct operation of the sea water pump, the proper flow of
water from the engine exhaust, all the lights on the instrument panel are off and there is no
audible alarm. Check also the oil pressure, coolant temperature and battery charging status.
6. If you heard strange noise, vibration or black smoke stop immediately the engine and refer to
assistance point.
7. Take the command of the boat.
8. Verify that all persons are on board and then engage the gear. Do not exceed the speed of the
engine during the first hours of operation!
On each occasion in which the engine is used for a long period at high revs, FNM® advises not to turn
it off at once, but to let it operate at low RPM without gear engaged for at least another two minutes in
order to facilitate gradual cooling of the stressed parts (turbine, etc..) avoiding any thermal stress.
FNM® HPE Series
41
2.4 Engine starting and stopping operations
Below are listed the operation to carry out for the normal operation of your FNM® HPE marine engine.
2.4.1 Preliminary operations at the ordinary engine startup
Make sure that the sea water inlet valve is open. The dry run of the sea water pump causes
irreparable damage to the impeller and serious damage to the engine after a few minutes of running.
Check the fluids levels:
-
Fuel
-
Engine oil
-
Coolant
Before starting the engine, make sure at last that in the engine room there is no presence of
combustible gases or vapors.
2.4.2 Engine ordinary use, analog panel
To carry out the engine ordinary startup, follow these instructions:
1. Check the indicator lights and the engine preheating
When turning the key to position (I) the alternator and oil pressure indicator lights are ON and
the alarm buzzer is ON.
42
FNM® HPE Series
Figure 12 - Situation of the panel with engine off, key to position I.
The glow plugs indicator light remains ON during this step until the engine pre-heating is
completed (according to the ambient temperature). After few seconds the light turns OFF. It is
now possible to start the engine (position II).
2. Start the engine.
Turn and hold the key in position (II) and release immediately when you hear that the engine
starts.
FNM® HPE Series
43
Figure 13 - Hold the key to position II until the engine starts.
Avoid the engine starter overload;; release the key after max 5 sec. if engine doesn’t start. Repeat the operation if necessary.
3. Engine functioning
While the engine is running (in normal functioning conditions) all the lights and the buzzer must
be OFF.
Figure 14 – The indicator lights on the panel are turned off when the engine is functioning properly.
44
FNM® HPE Series
4. Engine stop
Turn counterclockwise the key to position (0) to turn off the engine.
Figure 15 - Move the key to 0 to turn off the engine.
If the lights indicate the presence of a fault or an anomaly, immediately reduce speed
and turn off the engine. Consult paragraph 3.7.2 – Meaning of the indicators on the analog
panel – on page 112 and paragraph 3.7.4 – Troubleshooting – on page 120. Check and
resolve any problems before restarting to avoid serious engine damage.
2.4.3 Engine ordinary use, digital panel
To carry out the engine ordinary startup, follow these instructions:
FNM® HPE Series
45
1. Check the indicator lights and the engine preheating
When you turn the key in position (I) the instrument starts the automatic test and the display
shows "The Self Test Mode Is In Operation." The test mode lasts 10 seconds during which
time the buzzer sounds three times and the instrument flashes. Do not start the engine during
the instrument testing phase.
The
Self
Test
Mode
Is In
Operation
Figure 16 - Situation of the panel with engine off, key to position I.
The glow plugs alarm ("PRE HEAT CHECK" on the instrument or the related indicator light, if
included in the panel) is turned on during the initial phase until the complete pre-heating of the
engine (the time depends on ambient temperature). At the end of the preheating phase it turns
off.
Do not start the engine if the glow plugs alarm (or its indicator) is not turned off.
46
FNM® HPE Series
It is now possible to start the engine (position II).
2. Start the engine
Turn and hold the key in position (II) and release immediately when you hear that the engine
starts.
Figure 17 - Hold the key to position II until the engine starts.
Avoid the engine starter overload; release the key after max 5 sec. if engine doesn’t start. Repeat the operation if necessary.
The digital instrument sometimes (as in the case of low battery voltage) can redo the test mode.
3. Engine functioning
While the engine is running (in normal functioning conditions) all the lights and the buzzer must
be OFF.
FNM® HPE Series
47
VOLTS
13.8 Volts
Coolant Tmp
100° C
Figure 18 – The indicator lights on the panel are turned off when the engine is functioning properly.
The digital instrument is in normal operating mode, for default it shows the battery voltage
(Volts), the engine coolant temperature (Coolant Tmp).
4. Engine stop
Turn counterclockwise the key to position (0) to turn off the engine.
48
FNM® HPE Series
Figure 19 - Move the key to 0 to turn off the engine.
If the lights or the alarms of the CANBUS universal instrument indicate the presence of a
fault or an anomaly, immediately reduce speed and turn off the engine. Consult
paragraph 3.7.3 – Meaning of the indicators on the digital panel – on page 115 and
paragraph 3.7.4 – Troubleshooting – on page 120. Check and resolve any problems before
restarting to avoid serious engine damage.
FNM® HPE Series
49
2.5 Throttle
FNM® HPE marine engines are provided with an electronic throttle or with a mechanical throttle to
control the engagement of the gear and the engine acceleration.
2.5.1 Mechanical throttle
The mechanical throttle can be installed on a wall or console. It can also be equipped with a safety
lanyard that causes the engine shutdown in case of accidental departure of the driver from the boat.
Figure 20 - Wall mounted mechanical throttle
50
Figure 21- Mechanical throttle installed on the console (in single and twin-engine
configuration)
FNM® HPE Series
The mechanical throttle can also be provided with a security system that does not allow starting the
engine with the gear engaged. The purpose of this is to avoid inadvertently starting the engine with
propeller spinning causing damage to people in the water.
The elements of the mechanical throttle are as follows:
a. Neutral lock button - Prevents accidental gear engagement.
b. Throttle only button - With the command entered the throttle enables only the accelerator
without engaging the gear.
c. Lanyard stop switch - Turns off the engine in case the conductor accidentally moves away
from the driver's seat.
d. Control handle - Allows controlling the engines engaging the gear and acting on the
accelerator.
e. Trim/Tilt - Activates the trim pump.
f.
Trailer - Activates the trim pump and pulls the stern drive completely out of the water.
2.5.2 Flexball® electronic throttle
The electronic throttle works similarly as the mechanical throttle, allowing the command, depending on
the configuration, of one or two engines.
Moving the lever 16° forward or reverse from the neutral position, the system respectively engages the
forward or reverse gear. The accelerator has a stroke of 67° both in forwards or reverse gear.
FNM® HPE Series
51
Figure 23- Flexball®. electronic throttle stroke
Figure 22 - Flexball® electronic throttle for twin-engine.
On the lever there is a membrane control keypad consisting of 4 buttons and 4 status indicator LEDs.
52
FNM® HPE Series
Figure 24 - Flexball® .electronic throttle control keypad
In installations with single engine, both LEDs near the Engine buttons refer to the same engine. In
systems with two engines, the engine button and the corresponding LED refer to the physical location
on the keypad, namely: the button and the LED on the right refer to the right engine while the button
and the LED on the left refer to the left engine.
2.5.2.1 Acquisition of the command
The electronic throttle allows taking the control of the boat from any position, after the acquisition of
control with that position.
FNM® HPE Series
53
To acquire the command with stopped boat.
1. Position all the command stations in neutral;
2. Keep the Command button pressed for at least 1 second;
3. The Command LED will light and the Warm/Sync LED will begin blinking;
4. Now you are in the warm-up mode, i.e. the gearboxes are disabled. It is only possible to
accelerate to carry out the engines preheating operation;
5. To definitely take the command of the station you must reposition the levers in neutral position
and hold the Warm/Sync button for 2 seconds;
Now the command lever is enabled and ready for use.
To acquire the navigation command:
1. Synchronize the 2 levers of the station of which you want to acquire the command with respect
to the station which has the command;
2. the Engine led starts blinking when the lever of the calling station is in phase with the lever of
the station that has the command (with an accuracy of 10 degrees). ;
3. when both levers are synchronized (and therefore the corresponding Engine leds are blinking)
it is possible to acquire the command by pressing the Command button for 2 seconds.
54
FNM® HPE Series
Once finished the command acquisition procedure, the station is enabled to command the boat!
2.5.2.2 Engine Warm-up
If both levers are in neutral, by pressing for 3 seconds the Warm/Sync button of station which has the
command you enter in Warm-up mode. In Warm-up mode the Warm/Sync LED is blinking and it is
possible to accelerate the engine with clutch disengaged.
After positioning again both levers in neutral and pressing the Warm/Sync button for other 3 seconds
the function is disabled and the Warm/Sync LED stops flashing.
2.5.2.3 Synchro mode operation
This function is available only for twin-engine systems.
This function allows to command both engines at the same speed and direction with only one lever.
With both levers in neutral position, press the Engine buttons at the same time for 3 seconds. The
command of both engines is now on the right lever. In Synchro mode operation the Warm/Sync and
Command LEDs are always lighted on, except for the neutral position where all the LEDS are
permanently ON.
FNM® HPE Series
55
Bringing the two levers in neutral while pressing the Engine buttons for 3 seconds the command of the
individual engines will be assigned again to the respective levers. The Warm/Sync LED is off again.
2.5.2.4 Trim control unit (stern drive application)
Figure 25 - Trim control for twin engine installation.
Figure 26 - Trim control for single engine installation.
The trim command, if included in your configuration, can be activated by the Command Station by
means of the "+" and "-" buttons. The command signals are transferred to the Actuator from the
Command Station. The relay board mounted in the actuator enables the in-trim, trim-out and trailer
functions.
The “+” and “-“ buttons pressed together for at least 3 sec. activate the trailer function that allows to pull the stern drive totally out of water.
2.5.2.5 Emergency lever
In an emergency you can quickly disable the electronic system and command the propulsion engines
directly with the emergency mechanical levers that are already mounted on the actuator. Simply
unscrew the knob completely. This procedure will allow you to control the gearbox manually, using the
B levers, and with gas to a minimum.
56
FNM® HPE Series
Figure 27 - Electronic throttle control box emergency lever
2.5.2.6 ID Labels
Under the base of each command station a level there are n. 2 labels with the serial number and the
code of the command station.
2.5.2.7 Commands and meaning of indicator lights
Command
-
Signalling
Engine LED
-
Command LED
-
Warm/Sync LED
FNM® HPE Series
Meaning
If the LED is on, the corresponding propulsion engine is idle.
If it is OFF the Station does not command the system.
If it is ON the Station commands the system.
If the LED is blinking the navigation system is in WARM-UP mode that means that
the engines can be warmed up because the clutch is disengaged.
If the LED is lighted, the system is in Synchro mode. With the right lever both
57
58
Command
Signalling
Warm-up
-
Acquisition of the
command
-
-
All LEDs with
fixed light
Meaning
engines are controlled and the right trim device controls both trims (if any)
If both the levers of the Station which has the command are in neutral position and
you press for 3 seconds the warm/sync button, the WARM-UP function is
activated.
If you press the Command button for 3 seconds the station takes the command of
the system, only if the control lever is in neutral
Situation of system fault
FNM® HPE Series
2.6 Notes on daily use of the engine
Please follow these instructions to ensure the daily use of FNM® marine engines in total safety:
-
Take care to maintain the engine room dry and well aerated. Residual water in bilge could
vaporize and condensate on the engine, vapor created in this process damages the protection
varnish. Humidity and corrosive vapor damage the electrical connections. Bilge water may wet
engine parts during the boat navigation. The engine room shall be well aerated and the
aeration holes must guarantee a good air ventilation. In this way long life is guaranteed to the
engine protection varnish, to the plastic and rubber parts, increases the engine performances
and prevents excessive overheating of hot parts (exhaust, turbine, etc.).
Always keep the engine room dry and well ventilated!
-
The ventilation holes must ensure a good flow of air, but should prevent the entrance of salt,
water and dirt in the engine room. The seals of doors and hatches must prevent the entrance
of water in the engine room. Engine room ventilation, in respect of what discussed above,
could be even forced.
-
Take care of the distance between the turbocharger and the plastic part. The turbocharger
heats up during use and may damage the plastic and fiberglass parts (follow the installation
manual instructions). Insulate with a coating that ensures good thermal protection to structures
and bulkheads of the boat next to the hot parts of the engine to reduce the risk of fire.
-
Take care to oil or fuel leaks. The oil or fuel may come into contact with the turbocharger
during operation resulting in fire.
FNM® HPE Series
59
-
Take care to the turbocharger protection varnish. The housing of the turbocharger is painted
with heat resistant varnish. Excessive use and high temperatures could remove this protection.
Periodically check the housing of the turbocharger and, if necessary, spray with new varnish
resistant to high temperatures.
The turbocharger heats up during use. Be careful to avoid fire hazards.
Never rapidly increase the speed of the engine if the engine does not reach the correct
temperature.
-
Electrical and electronic parts are affected by moisture and the attack of corrosive agents. Pay
attention to the state of battery charge, recharge during the engine inactivity, if required
periodically. Maintain the battery compartment aerated and dry to avoid risk of fire.
-
Discharge the sea water circuit by draining through the zinc anodes if the engine isn’t utilized for a long time and if exposed to high temperature.
Take care, avoid short-circuits. Short circuit can cause damage to people and engine
parts. Toxic and flammable vapors may be created in the battery compartment, aerate
the battery compartment. Avoid all risks of fire.
60
FNM® HPE Series
3 Maintenance of FNM® engines, HPE Series
FNM® HPE Series
61
3.1 General information on maintenance
FNM® marine engines of HPE class require some regular operations to ensure long engine life and
avoid incurring the dangers to the engine itself and the people on board.
3.1.1 Staff responsible for maintenance
The pages will describe the procedures necessary to carry out regular maintenance.
The control and maintenance operations indicated below require training, competence and compliance
with the standards required for safety; therefore they must be completed by staff involved, as indicated
below.
Ordinary maintenance: made by the boat user and the workshop staff. The interventions are
marked by the symbol shown on the side.
Periodic maintenance: performed by qualified personnel equipped with appropriate work tools
and adequate means of protection. These interventions are marked by the symbol shown on
the side.
Extraordinary maintenance: performed by qualified staff and authorized FNM® service
centers, in possession of detailed technical information and specific equipment. Interventions
identified by the symbol shown on the side.
It is necessary, to carry out every maintenance operation, taking note of all the operations carried out
in the Warranty and Maintenance booklet attached to the end of this manual (page 129).
62
FNM® HPE Series
3.1.2 Safety
Carefully follow the instructions below for each operations that you are going to do on FNM®
diesel marine engines.
-
Always wear safety shoes and overalls.
-
Do not wear loose clothing, rings, bracelets and/or necklaces near engines or moving parts.
-
Wear protective gloves and goggles during these operations:
o
filling batteries with acid solutions;
o
supply with inhibitors or anti-freeze;
o
replacement or supply of the lubricating oil.
Hot engine oil can cause burns. It is recommended to carry out the interventions only
when it has reached a temperature below 50°C.
-
When working in the engine room, pay the utmost attention to your movements to prevent
contact with rotating or high temperature parts.
-
Wear goggles when using compressed air.
The maximum air pressure used to clean is equal to 200kPa (2bar, 30psi, 2kg/cm2).
-
Wear a protective helmet when working in an area with suspended loads, or with systems at
height of the head.
FNM® HPE Series
63
-
Use protective cream on your hands.
-
Replace immediately your suit if wet.
-
Keep the engine clean at all times, removing stains of oil, gas and coolants.
-
Put used rags in fireproof containers.
-
Do not leave foreign objects on the engine.
-
Prepare adequate and safe containers to collect exhaust oil.
-
After a repair, take appropriate measures to stop the intake of air from the engine when, after
starting, there is an uncontrolled increase in the engine rpm.
Avoid maintenance in the presence of electrical voltage: check the effective grounding
of all the equipment. During diagnostic operations and maintenance make sure you have
hands and feet dry whenever possible and use insulating boards.
64
FNM® HPE Series
3.2 Periodic organization and frequency of maintenance operations
FNM® HPE marine engines require periodic maintenance to be kept always efficient.
The maintenance table is shown in the following pages. The first two lines refer to inspections and
operations that the user can and must do. The remaining operations are handled by technical staff or
an authorized FNM® service point.
To avoid voiding the original warranty of your HPE engine always make interventions be carried out on
the engine by the staff of a FNM® authorized service point.
For information about individual maintenance operations See section 3.3 - Details of maintenance
operations - on page 68.
FNM® HPE Series
65
User Operations
| Operazioni
dell’Utente
-
FNM First
Service | Primo
Tagliando FNM
Tagliando
Annuale FNM |
FNM Annual
Service
FNM Advanced
Service |
Tagliando
Avanzato FNM
Wintering |
Invernaggio
Before first start
after wintering |
Prima dell'avvio
dopo
l'invernaggio
66
Engine and propellers shafts lubrification |
Lubrificazione degli alberi motore ed elica
Every 10h |
Ogni 10h
Oil change (engine and trasmissions) |
Cambio olio (motore e trasmissione)
User Inspection
| Ispezione
dell’Utente
Air filter replacement | Sostituzione filtro
aria
Running hours |
Ore di moto
Diesel filter replacement | Sostituzione filtro
gasolio
Scheduled
Interventions 1/3
First 30h |Prime
30h
X
X
X
X
X
X
X
Every 100h |
Ogni 100h
Ogni anno |
Every year
X
X
X
X
X
X
X
Every 800h |
Ogni 800h
Every 2 years |
Ogni 2 anni
-
-
Fluid leaks inspection | Verifica delle
perdite fluidi
X
X
X
X
X
X
X
X
X
X
X
X
X
Auxiliaries Drive Belts inspection and
tensioning | Ispezione e tensionamento
delle cinghie ausiliaria
Engine re-alignement and suspensions
tightening | Riallineamento motore e
serraggio supporti elastici
Andodes inspection | Verifica consumo
anodi
Raw water filters cleaning | Pulizia dei filtri
acqua mare
X
Check battery status | Verifica stato batteria
Coolant level inspection | Verifica liquido
refrigerante
X
Diesel filter inspection and draining |
Ispezione e drenaggio filtro gasolio
Oil levels inspection (engine and
transmissions) | Verifica livelli olio (motore
e trasmissione)
Alternatively |
Alternativa
Before engine
starts | Prima di
ogni partenza
Ogni settimana
durante l'uso |
Every week
during use
X
X
FNM® HPE Series
User Inspection |
Ispezione
dell’Utente
User Operations
| Operazioni
dell’Utente
Raw water pump impeller inspection |
Ispezione della girante pompa acqua mare
FNM First
Service | Primo
Tagliando FNM
Tagliando
Annuale FNM |
FNM Annual
Service
FNM Advanced
Service |
Tagliando
Avanzato FNM
Wintering |
Invernaggio
Before first start
after wintering |
Prima dell'avvio
dopo
l'invernaggio
Every 10h | Ogni
10h
Wiring inspection | Ispezione cablaggio
Running hours |
Ore di moto
Blots tightening | Serraggio bulloneria
Scheduled
Interventions 2/3
-
First 30h |Prime
30h
X
X
X
Every 100h |
Ogni 100h
Ogni anno |
Every year
X
X
X
Every 800h |
Ogni 800h
Every 2 years |
Ogni 2 anni
-
-
FNM® HPE Series
Anodes rplacement | Sostituzione degli
anodi
Raw water circuit cleaning | Pulizia del
circuito acqua mare
Oil filter replacement | Cambio filtro olio
Raw water pump impeller replacement |
Sostituzione girante pompa acqua mare
Exchanger pipes cleaning | Pulizia fasci
tubieri
Mechanical couplings inspection and
lubrication | Ispezione e lubrificazione
accoppiamenti meccanici
Starter pinion greasing | Ingrassaggio
pignone motorino di avviamento
Mercathode® system check (if available) |
Verifica del sistema Mercathode® (se
presente)
Steering system greasing | Ingrassaggio
sistema sterzante
Alternatively |
Alternativa
Before engine
starts | Prima di
ogni partenza
Ogni settimana
durante l'uso |
Every week
during use
X
X
X
X
X
X
X
X
X
X
X
X
X
X
67
Running hours |
Ore di moto
User Inspection
| Ispezione
dell’Utente
Every 10h | Ogni
10h
User Operations
| Operazioni
dell’Utente
-
FNM First
Service | Primo
Tagliando FNM
Tagliando
Annuale FNM |
FNM Annual
Service
FNM Advanced
Service |
Tagliando
Avanzato FNM
Wintering |
Invernaggio
Before first start
after wintering |
Prima dell'avvio
dopo
l'invernaggio
68
Ogni anno |
Every year
Every 800h |
Ogni 800h
Every 2 years |
Ogni 2 anni
-
X
X
X
X
X
X
X
X
X
X
Engine cleaning for salt removal and antirust
treatment | Pulizia del motore per rimozione
salsedine e trattamento antiruggine
Electrical wiring reconnection |
Riconnessione cablaggio elettrico
Fuel tank cleaning | Pulizia serbatoio
carburante
Raw water antifreeze additive addition (if
needed) | Aggiunta additivo antigelo acqua
mare (se necessario)
Coolant antifreeze additive addition (if
needed) | Aggiunta additivo antigelo liquido
di raffreddamento
Turbine inspection and actuators greasing (if
present) | Ispezione turbina e ingrassaggio
attuatore (se presente)
Raw water pump impeller greasing |
Ingrassaggio girante pompa acqua mare
X
Electrical wiring disconnection |
Disconnessione cablaggio elettrico
X
Diesel antifreeze additive (if needed) |
Additivo antigelo carburante (se necessario)
Thermostat replacing | Sostituzione valvole
termostatiche
Every 100h |
Ogni 100h
Flexible coupling inspection | Ispezione
parastrappi
-
Coolant replacement | Sostituzione liquido
refrigerante
First 30h |Prime
30h
Distribution belt-thigteners and belts
replacement | Sostituzione cinghie e
tendicinghie distribuzione
Alternatively |
Alternativa
Before engine
starts | Prima di
ogni partenza
Ogni settimana
durante l'uso |
Every week
during use
Auxiliaries drive belts replacement |
Sostituzione cinghie ausiliari
Scheduled
Interventions 3/3
X
X
X
FNM® HPE Series
3.3 Details of maintenance operations
3.3.1 Engine and transmission oil levels check
Ordinary maintenance: made by the boat user and the workshop staff.
For topping up the oil levels only uses the type specified in paragraph 3.4 - Engine treatment and
maintenance products – on page 98.
3.3.1.1 Engine oil level check
The engines are filled by the manufacturer sent with the correct amount of oil: in many cases it
is not necessary to fill the engine with oil. However, some installations may affect the reading of
the oil level in the sump because of the particular circumstances of inclination. If your engine oil
level has is abnormal at the delivery, inform your installer.
To check the engine oil level:
Before working on the engine or entering inside the engine compartment, please make
sure you read the safety instructions.
1. Make sure that the engine is stopped from at least 5 minutes to support the complete draining
of oil in the sump.
2. Extract the oil dipstick from the oil dipstick tube and clean it with blotting paper or similar.
3. Reintroduce the oil dipstick in the guide pipe, take it out and check the level.
FNM® HPE Series
69
A: If the oil level is between A and B it is not necessary to
refill.
B: If the level of the indicator is less than B it is necessary to
refill.
C: If the oil is at level C or lower, it is necessary to refill up to
level A if possible, in any case the level must be equal to or
greater than B.
Figure 28- Terminal part of the oil dipstick
The level should never exceed the reference A. The oil topping up is made through the oil fill cap on
the engine.
During the use and the storage of lubricating oil take care for water and dirt
contamination .Take care to avoid the entrance of contaminants (debris, water) during oil
refilling.
To measure the engine oil level pay attention to the engine inclination both longitudinally and laterally.
Do not exceed 3° the horizontal inclination during the test (do not make the measurement in the
presence of excessive loads on the bow - stern or starboard-port side of the boat such as to distort the
test overtilting the boat-engine assembly.
The engine is delivered with the correct amount of oil (MAX) excessive angles can distort the reading.
For installation with high angles, make a reference mark on the level dipstick corresponding to the
level achieved (with the maximum amount of oil as shipped by the manufacturer).
70
FNM® HPE Series
3.3.1.2 Transmission oil level check
To check the transmission oil level refer to the user manual provided by the manufacturer of your
transmission.
3.3.2 Coolant level check
Ordinary maintenance: made by the boat user and the workshop staff.
To verify the coolant liquid level, take care to the boat and/or engine inclination.
1. Unscrew the coolant fill cap, then check that the fluid level is between minimum and maximum
limits (if present), or not excessively low.
2. If necessary top up to a maximum level.
In any case the coolant liquid level must be over the engine head to ensure a correct operation.
Always verify the good seal of the filter cap to avoid leakage after reassembly.
Never refill the coolant circuit with sea water!
Be careful when opening the cap of the expansion tank: pressurized liquid may splash
out and cause damage to property or persons.
FNM® HPE Series
71
3.3.3 Cleaning and inspection of sea water filters
Ordinary maintenance: made by the boat user and the workshop staff.
During the engine period of use check daily the sea water filter. The filter should allow the smooth
passage of water (100 liters/minute at 4000 RPM). Also check that the seawater intakes are clean
from elements that can block the passage of water.
Close the sea water intake valve when you dismount the filter.
For the filter cleaning:
1. Open the sea water intake cap after closing the valve.
Figure 29 - Sea water filter
72
FNM® HPE Series
2. Clean or wash the filter with fresh water to remove the clogging elements.
Figure 32 - Sea water filter cleaning under running water
3. Re-close the filter and check for any leaks.
Always verify for the good seal of the filter cap to avoid leakage after reassembly.
3.3.4 Fluids leakage check
Ordinary maintenance: made by the boat user and the workshop staff.
Periodically check that the engine does not lose any kind of fluid before, during and after its operation.
FNM® HPE Series
73
Check if there are drips from the engine on the bottom of the engine compartment, if there are leaks
from tanks and hoses and that all the ducts that depart from the engine (sea water, fuel, steering oil)
are free of condensation.
When there is excessive reduction of any level while using the engine, immediately shut down
the engine and find the source of the leak.
3.3.5 Fuel filter draining and inspection
Ordinary maintenance: made by the boat user and the workshop staff.
The fuel filter of your engine may be on the engine itself, or be placed on the wall in the engine
compartment (HPE/P 300).
To drain the fuel filter:
1. Remove the water in fuel presence sensor plug from under the filter.
74
FNM® HPE Series
Figure 30 - Removing the water in fuel presence sensor
2. Use a small clean container of about half a liter to collect diesel fuel in excess.
Don’t smoke during the operations.
3. Unscrew the drain cap under the filter ad wait that fuel comes out. Close when you notice that
the fuel is clean and free of impurities or contamination of water.
Fuels such as waste oils are highly polluting. Respect the
environment and pay attention to the disposal of oil.
4.
Replace the cover re-screwing it and replace the sensor connector.
In the low pressure circuit diesel fuel is kept under pressure by the electric pump. Be careful to
avoid the formation of air bubbles in this part of the circuit, otherwise you will have irregular
operation of the engine. To put the circuit under pressure after the drainage operations turn the
ignition key to position (I) and wait that the electric pump stops working, before turning on.
FNM® HPE Series
75
Repeat the operation if necessary.
3.3.6 Battery status check
Ordinary maintenance: made by the boat user and the workshop staff.
Be careful when operating near the battery compartment. Disconnect the battery cables
before working on it.
Do not smoke near the battery. Flammable gases could be left by the battery.
3.3.6.1 Batteries that are maintenance-free
This type of battery is equipped with an indicator of the battery charge status (1). Depending on the
color of the indicator you can see the level of battery charge:
76
FNM® HPE Series
Green color: charge level above 65%. No maintenance
required.
Dark color: charge level below 65%. Recharge immediately.
Yellow color: replace the battery.
Figure 31 - Maintenance free batteries
The data are for information, always read the producer’s instructions.
Never try to refill with any type of fluid with this type of battery.
3.3.6.2 Traditional lead-acid batteries
To check the electrolyte level refer to the level marks on the battery side.
To refill:
1. Remove the caps on the upper part.
FNM® HPE Series
77
Figure 32 - Traditional lead-acid batteries
Acid liquids contained, use appropriate protections!
2. The electrolyte level should cover the plates.
3. If the level is insufficient, fill up to Max level with distilled water.
4. Replace the caps after the charging cycle.
Battery state of charge could influence the engine performance. Avoid discharging excessively
the batteries.
Grease the battery poles with basic grease periodically. The battery electrolyte status can be
measured with a manual densimeter.
78
FNM® HPE Series
3.3.7 Anodes consumption check and replacement
Ordinary maintenance: made by the boat user and the workshop staff.
Zinc anodes prevent oxidation of engine metal parts. They are positioned in different parts of the sea
water circuit. Replace the anodes if the sacrificial zinc cartridge (see the picture below) is consumed
over the 50% (the length of the new part is around 15 mm). The zincs consumption depends on many
ambient factors and engine connections. FNM® uses pure zinc anodes that can be used in the marine
environment.
Figure 33 - Zinc anode
Follow the instruction to disassemble:
1. Stop the engine
2. Unscrew the anodes only after closing the sea water circuit valve.
3. Replace the anodes if the consumption of the sacrificial part is greater than 50% (less than 8
mm). Together with the anodes replace also the copper washer. In the re-tightening always
use thread sealant type LOXEAL 1810.
FNM® HPE Series
79
Take care when reassembling to maintain the electrical continuity (contact between the metal
parts).
4. Reopen the sea water circuit and verify for leaks.
3.3.8 Fuel filter replacement
Ordinary maintenance: made by the boat user and the workshop staff.
To replace the fuel filter follow the instructions:
1. Turn OFF the engine and take care to close the fuel suction line.
2. Let the engine cool down if it is hot.
3. Prepare a container to collect any leaks.
4. Remove the sensor plug and the sensor from the filter (take care to gasket). Pay attention to
possible fuel leakage.
80
FNM® HPE Series
Figure 34 - Removing the water in fuel presence sensor
5. Unscrew the filter using the appropriate wrench.
Be careful to follow procedures for disposal of the fuel
filter in accordance with regulations.
6. Assemble the sensor on new filter and tighten the lower cap.
7. Fill the new filter with fuel.
8. Reassemble filter on the engine and open the fuel supply circuit.
9. Bleed the fuel supply circuit. Turn the key to (I) position and wait few seconds until the low
pressure electric pump takes the circuit under pressure again. Repeat the operation if
necessary.
10. Start the engine and check for any leaks.
FNM® HPE Series
81
Don’t smoke during the assembly-disassembly operations!
3.3.9 Air filter cleaning or replacement
Ordinary maintenance: made by the boat user and the workshop staff.
The air filter integrity and cleaning is important for the engine life and performances. FNM® engine
series air filters are developed for marine applications When cleaning the filter elements only with
compressed air, never use pressures above 2 bar to avoid damaging them (filters are dry and need no
film of oil on the filtering part).
To remove the air filter:
1. Stop the engine
2. Loosen the collar at the base of the filter
3. Pull out the air filter
4. Clean the filtering sponge, or replace the part. For the HPE/P 300 engine alternatively it is
possible to clean the metal filter with appropriate products.
5. Reassemble the filter and tighten the collar
82
FNM® HPE Series
Never start the engine without the air filter in place! It can produce serious damage to
the engine.
3.3.10 Engine and transmission oil change
Ordinary maintenance: made by the boat user and the workshop staff.
To change engine and transmission oil, comply with the procedures listed below:
3.3.10.1
Engine oil change
1. Turn off the engine.
2. If you have used recently used it, let the engine cool down for at least 20 minutes, to help oil
flowing in the sump.
3. Prepare a container of proper capacity to collect exhaust oil
4. Connect a hose to the drain valve on the sump. The exhaust valve position changes depending
on the model of your engine, and is indicated in Chapter 1.6 - Main components of FNM®
engine, HPE Series – on page 15.
5. Connect a pump to the hose end, then open the drain valve.
6. Open the oil refill cap to facilitate the suction. The cap is located on top of the engine and is
described in section 1.6 - Main components of FNM® engine, HPE Series – on page 15.
7. Operate on the pump to transfer the oil.
®
FNM HPE Series
83
8. Disconnect the pump and close the valve.
9. Refill the engine with new oil up to proper level.
Respect the environment. Exhaust oils are strongly
polluting .Follow the local regulations for disposal.
3.3.10.2
Transmission oil change
To properly change oil in your transmission, carefully follow the instructions indicated in the use and
maintenance manual of the manufacturer. You can refer to Chapter 3.7.1 - Specifications of
transmissions on page 110 for specifications on oil to use.
3.3.11 Service belts inspection and tensioning
Ordinary maintenance: made by the boat user and the workshop staff.
Always be careful when working on the belts.
To check the status of the service belt it is necessary to remove the belts cover from your engine.
Follow the instructions:
1. Remove the cover located on the front of the engine.
Attention: In case of HPE/P 40/150/150JD/170/170JD/190/190JD and HPEL 65/90 it is also
necessary to remove the whole intercooler and its support.
84
FNM® HPE Series
Attention: In case of HPE 80/80SD/110/110JD and HPEL 45 it is necessary instead to remove
the sea water pump fixing unit.
2. Loosen the belt tensioner.
3. Verify the belt status. If it is worn, as shown in the figure, it should be replaced.
Figure 35 - Worn service belt
4. Reassemble the belt, then tighten the tensioner.
5. Reassemble the belt cover.
FNM® HPE Series
85
3.3.12 Sea water pump impeller inspection and replacement
Periodic maintenance: performed by qualified personnel equipped with appropriate work tools
and adequate means of protection.
The position of the sea water pump varies depending on the model of your engine. You can verify the
position in paragraph 1.6 - Main components of FNM® engine, HPE Series – on page 15. The pump
shaft is driven in rotation by the movement of the crankshaft. The function of the sea water pump is to
draw water from the sea intake and to put it into circulation in the cooling systems (heat exchangers,
exhaust manifold, etc..). Water circulation is ensured by the rotation of a rubber impeller (nitrile) into
the center housing of the pump. The indications on the suction side are shown on the cover of the
pump.
The impeller never rotates without water for more than 1 minute, dry rotation increase the
impeller temperature and quickly wears the vanes.
Pay attention to the extreme conditions of the impeller to prevent engine overheating.
It is necessary that you have a backup impeller on board to replace in case of damage during
navigation.
To dismount the impeller :
1. Stop the engine and close the sea water intake valve.
2. Remove the fastening screws from pump cap (take care to the gasket).
86
FNM® HPE Series
3. Remove the impeller with the appropriate puller. Mark the impeller with a pen on the side at
sight to reposition it (only if it isn’t damaged) in the same way.
4. If the impeller is too worn, provide for replacement.
5. When using a new impeller, lubricate it with silicon spray grease before mounting it.
Figure 36 - Lubrication of the impeller
6. Install the new impeller on the grooved shaft.
7. Re-close the pump cap and replace the seal gasket if possible.
8. Open the sea water intake valve.
9. Restart the engine and check for any leaks.
Use only original FNM spare parts.
FNM® HPE Series
87
3.3.13 Sea water circuit cleaning
Periodic maintenance: performed by qualified personnel equipped with appropriate work tools
and adequate means of protection.
Keep sea water circuits clean from salt deposits and from any external intrusion to ensure proper
cooling of the engine.
In any case you should run the engine with fresh water for at least 5 minutes every 50 hours, in order
to prevent the accumulation of salt deposits in the cooling circuits related to the sea water section.
The seawater system cleaning must be done even during the winter season operations.
After flushing the circuits and after circulated fresh water in the cooling circuit (sea water circulation
side), to avoid freezing during long rest of the engine in cold weather conditions, we recommend to:
1. Close the sea water tap
2. Open the sea water filter cap
88
FNM® HPE Series
Figure 37 - Sea water filter opening
3. Insert the antifreeze liquid (antifreeze mixture) in the filter and put the engine to minimum rpm
to facilitate the antifreeze additive aspiration in the cooling circuits up to overboard discharge.
In the case of applications with stern drive follow the same operation using the casings on the suction
intakes of the stern drive and sucking from a tank containing the antifreeze mixture.
FNM® HPE Series
89
Figure 38 - Casings for cleaning the circuit in applications with stern drive
The coolant fluid is polluting. Use appropriate precautions
to avoid releasing it into rivers or the sea!
The sea water freezing in the cooling circuit causes damage to the circuit itself.
During the winter in areas where temperatures are particularly cold you should follow the instructions
below to avoid the circuit freezing when the engine is not used for short periods.
1. Drain the circuit.
2. Close the sea water intake valve.
3. Unscrew the zinc anodes on the cover of the water to water exchanger and on the intercooler
cover. Facilitate the release of water from the circuit by unscrewing also the anode on the
cover of the exhaust manifold.
90
FNM® HPE Series
3.3.14 Oil filter change
Ordinary maintenance: made by the boat user and the workshop staff.
To change the oil filter, follow the instructions carefully:
1. Turn off the engine and let it cool down adequately.
2. Prepare a container to collect any leaks.
Take care to dismount the oil filter only after removing oil from the sump during the engine oil
change operation.
3. Unscrew the filter using the appropriate wrench.
4. Clean the housing with blotting paper or a dry cloth.
5.
Lubricate the rubber O-ring seal and the ring seat before remounting the filter cover.
FNM® HPE Series
91
Figure 39 - New oil filter lubrication
6. Reposition the new filter and re-screw it. Fill the engine with new oil.
7. Turn the engine ON and leave it running at minimum RPM for few minutes until it reaches the
working temperature. Increase the speed until reaching the maximum and check the oil
pressure level.
8. Check for any leaks.
Respect the environment. Exhaust oils are strongly
polluting .Follow the local regulations for disposal.
92
FNM® HPE Series
3.3.15 Cleaning the tube bundles
Periodic maintenance: performed by qualified personnel equipped with appropriate work tools
and adequate means of protection.
Your marine engine is equipped with a different tube bundle exchangers for cooling different fluid
circuits and improve overall performance.
Each of these must be thoroughly cleaned to prevent incrustations that after long time can block the
fluid flow and lead to engine damage.
3.3.15.1
Cleaning the tube bundle of the water to water exchanger
To clean the tube bundle follow these indications:
1. Stop the engine and close the sea water circuit inlet valve.
2. Drain the sea water circuit as described in Section 3.3.13 - Sea water circuit cleaning - on page
87.
3. Drain the coolant from the circuit and disassemble the pipes.
4. Remove the water to water exchanger from its support (see the paragraph 1.6 - Main
components of FNM® engine, HPE Series – on page 15 to identify the heat exchanger).
5. Dismount the covers of the exchanger.
6. Take care of the seal gaskets, respect their integrity. In any case, replace them if damaged.
FNM® HPE Series
93
7. Remove the bundle and clean the pipes with a brush. Pay attention to the two O - rings.
8.
After cleaning, re-assemble the assembly, replacing the seal gaskets.
Verify the exchanger seal after the assembly!
9. Reposition the exchanger on the bracket.
10. Reposition the pipes and seal collars.
11. Fill the coolant circuit.
12. Start the engine, letting it warm up to 80°C.
13. . Check for any leaks and if necessary drain air from the circuit.
3.3.15.2
Cleaning the intercooler tube bundle
To clean the intercooler follow these instructions:
1. Stop the engine and let it cool down adequately.
2. Drain the circuit unscrewing the anodes as described in section 3.3.13 - Sea water circuit
cleaning – on page 87.
3. Unscrew the collars of the intercooler hoses (see the section 1.6 - Main components of FNM®
engine, HPE Series – on page 15 to identify the intercooler) and pull it out.
94
FNM® HPE Series
4. Remove the cap. Pay attention not to damage the seal gaskets.
5. Pull off the tube bundle. Pay attention to the fins during the tube bundle dismounting operations,
to not affect the exchanger performances.
6. Clean inside the tubes with a cleaning brush, remove any salt incrustations and wash with
fresh water.
7. Clean the outer part and the fins of the tube bundle from oil deposits using fuel and then dry
preferably with compressed air (max. 2 bar).
8. Reposition the tube bundle in the housing (take care of the fins during the bundle placing in the
casing). Properly position all the gaskets and the O-rings into the housing at the base of the
casing.
9. Reposition the cap.
10. Reposition the inlet pipes and screw the pipe clamps.
11. Verify for any leaks after tightening the screws.
3.3.15.3
Cleaning the fuel exchanger
To clean the exchanger follow the instructions:
1. Stop the engine and close the sea water circuit valve.
2. Empty the sea water circuit by unscrewing the anodes as described in paragraph 3.3.13 - Sea
water circuit cleaning – on page 87.
FNM® HPE Series
95
3. Remove the sleeves and covers of the fuel exchanger (see paragraph 1.6 - Main components
of FNM® engine, HPE Series – on page 15 to identify it).
4. Clean inside the tubes with a cleaning brush and rinse with water.
5. Reposition the lateral caps (take care to gaskets).
6. Check for any leaks.
3.3.16 Grease the engine starter pinion
Periodic maintenance: performed by qualified personnel equipped with appropriate work tools
and adequate means of protection.
The pinion of the starter must be greased with grease for gears.
During engine operation grease is expelled from the pinion, so the pinion must be greased periodically.
Unscrew the mounting screws and disconnect the electrical connections of the starter.
96
FNM® HPE Series
Figure 40 - Electrical wiring of the starter
Remove the starter from the housing.
Clean the pinion with paper or a clean cloth and grease again.
Figure 41- Starter pinion
Reassemble the starter and electrical connections.
FNM® HPE Series
97
3.3.17 Other advanced maintenance operations
Periodic and extraordinary maintenance: The following operations can be performed only by
qualified and authorized FNM® service centers, in possession of detailed technical information
and specific equipment.
-
98
Lubrication of the crankshaft and propeller.
Engine alignment and engine mounts retorque.
Bolts tightening.
Wiring inspection.
Mechanical couplings inspection and lubrication.
Mercathode® system verification.
Steering system greasing.
Auxiliary belts replacement.
Timing belts, timing belts tensioners and timing chain tensioners replacement.
Engine coolant replacement.
Flexible coupler inspection.
Thermostatic valves replacement.
Antifreeze fuel additive.
Electrical wiring disconnection.
Turbine inspection and actuator greasing (if present).
Fuel tank cleaning.
Engine cleaning to remove salt and anti-rust treatment.
Electrical wiring reconnection.
FNM® HPE Series
3.4 Engine treatment and maintenance products
Here are some warnings on the type and quality of products to be used for normal engine treatment.
3.4.1 Maintenance products
For the engine maintenance products read and follow the instructions indicated by producers or turn to
FNM service. Some products and use are linked to the operating temperatures.
Type of fluid
Engine oil
Transmission oil for ZF gearbox
Transmission oil for Technodrive gearbox
Transmission oil for Mercruiser stern drive
Engine oil additive
Fuel additive (long storage)
Fuel winter storage
Fuel Additive
Metal protector/unlocker
Grease for gears
Turbine lubrication
Engine oil long storage, washing, cylinders
antirust
FNM® HPE Series
Recommended product
FNM® XTC SAE 5w40 Synthetic
Bardahl® XTC SAE 5w40 Synthetic
Consult section 3.7.1 – Transmission
specifications– on page 110
Bardahl® 2 Oil Treatment
BARDAHL® DAB or IOSSO Fuel Anti Bacterial
Bardahl® Diesel Antifreeze
Bardahl® Diesel Injector Cleaner
Bardahl® Spray K9
Bardahl® Viscogrease
ZEP® 2000 Grease Spray
ZEP® Red lithium grease
Vanguard® Storage 30 oil MIL-L-2104B
99
Be careful not to mix different types of engine oil. FNM® engine oil equivalent characteristics
recommended: Synthetic Multigrade SAE5W40 - ACEA A3-B3-B4, API SL SM CF, MB 229.3, VW
505.00-502.00, BMW Longlife 98.
Recommended products:
3.4.2 Fuel characteristics
Use only commercially available diesel according to DIN EN 590.
Winter diesel fuel: For winter use, (if used at temperatures lower than 0°C), common diesel fuel may
cause problems because it may become too dense and thick because of paraffin freezing. For this
reason, during the winter we suggest that you use winter diesel fuel or antifreeze additives for diesel
fuel. In fact, you may use this type of fuel without any problems up to temperatures between –15° C
and –22° C. In countries with a different climate, it is usually possible to find types of diesel fuel with
different thermal properties.
3.4.3 Paint
For engine maintenance (avoid to spray the turbocharger) and touch up of small rusted parts, use
acrylic polyurethane-based paint RAL 9006.
For rusted engine parts:
100
FNM® HPE Series
-
Remove the rust with abrasive paper or similar until the surface is perfectly clean.
-
Clean the surface accurately.
-
Spray the paint (follow the producer instructions).
Paint is commonly toxic and flammable, take care during use. Aerate the room and read the
producer’s instructions.
3.4.4 Cleaning the panel
FNM® panels are specially designed for the marine environment. Avoid using strong cleaning agents
to clean them to prevent damage to surface finishes.
FNM® HPE Series
101
3.5 Periods of engine inactivity
If the engine remains inactive for a long period you need to protect it from oxidation and freezing;
FNM® advises its customers who want to personally carry out the preparatory work to the inactivity of
the engine, to follow the instructions below.
3.5.1 Operations to prepare the engine inactivity
1. Dismount, clean and remount the heat exchangers, preventing in this way to leave them
exposed to oxidizing substances. Check and if necessary replace the zinc anodes.
2. Dismount and spray the sea water pump impeller with silicon grease spray or replace if
necessary.
3. Connect the engine suction line to the fresh water line. Take care to the water flow: the sea
water pump flow at maximum engine speed is around 100 liters / min. Let the engine run for
about 15 min at 800 RPM to aid the circuit cleaning.
4. Fill a proper tank with an opportune mixture of water and antifreeze fluid (depending on the
degree of protection that you would like to offer circuits) and connect the sea water suction
pipe to the tank. Start the engine at 800 RPM and wait for the mixture, sucked by the pump, to
fill completely the sea water circuit (until it comes out of the exhaust riser).
5. Drain the old oil from the sump and fill with clean oil appropriate for cleaning. Then start the
engine (when the engine is still warm, drain the oil that is in the sump, and repeat the operation:
this oil can be used for another two or three times). After the lubrication circuits washing
operation, drain again and fill the engine with new oil, properly added with the proper additives
till the oil level indicated by the dipstick is correct.
102
FNM® HPE Series
For the oil treatment FNM® advises Bardahl® Oil Treatment for long storage; while for washing
and storage it recommends Vanguard® Storage 30 oil MIL-L-2104B.
6. After filling with oil and any additive, start the engine and run for about 15 min at minimum
RPM to support lubrication of the engine internal mechanism.
7. Check the coolant. Drain the circuit and fill with the proper mixture of antifreeze.
Read the coolant producer instructions and the mixing table!
8. Check the fuel tank for dirt or deposits, if necessary clean it.
During the end of season or before the engine storage, if possible, add an injector cleaning
additive to the fuel and take care to leave the tank empty after the treatment and cleaning.
FNM® advises Bardahl injector cleaner.
Respect the environment, do throw away pollutants
9. Dismount the fuel filter and clean it, if necessary replace it. Fill the fuel filter with a proper
mixture of fuel and additive for injector cleaning (leave empty if new).
FNM® HPE Series
103
10. Fill a tank with a proper mixture of fuel and injectors additive, like Bardahl® Injector Cleaner.
Connect the fuel suction hose to the tank return line. Run the engine for some minutes at the
minimum speed.
11. To prevent cylinders rusting, FNM® advises to spray or nebulize Vanguard® storage 30
protective oil (MIL-L-2104, MIL-L-21260A) through the suction manifold (dismounted air filter)
and spin the engine without starting it to facilitate oil suction (this operation can be carried out
by spinning the starter motor and consequently the engine with the fuel supply line
disconnected to avoid starting and to facilitate only the movement/lubrication of the internal
parts).
12. Disconnect the electrical connections. Push the red stop button on the ECU box .
13. Clean the engine metal parts and spray the engine metal parts and the engine leverages with a
protective/unlocking spray to prevent rust. FNM® advises to use Bardahl® K9spray.
14. Lubricate the starter pinion and the mechanical connections (grooved joints, etc.)
15. Dismount the belts and store them preventing their deformation.
16. Disconnect the fuel line (inlet and outlet).
17. Spray the electrical connections with electrical connections protective spray.
18. Store the engine in a well aerated place avoiding humidity and steam to prevent rust forming.
19. For long storage of fuel in tank, FNM® advises to use Bardahl® DAB or IOSSO® Diesel fuel
antibacterial additives to prevent the proliferation of algae and deposits.
104
FNM® HPE Series
20. For fuel winter storage, FNM® advises (for very cold storage) to use diesel fuel antifreeze
additive. FNM® advises use of Bardahl® Diesel Antifreeze.
Take care of the engine storage room out of the boat or maintain the boat engine room dry and
free from salt vapor.
3.5.2 Operations to restore the engine after periods of inactivity
After a period of inactivity, it is necessary to carry out few maintenance interventions before starting
the engine again to ensure its efficiency and duration.
1. Verify the battery charge level conditions. Make sure that the battery voltage is greater than 12
Volt.
2. -Make sure that the electric contacts are intact and properly greased with basic grease. Assure
the correct electrical connections.
3. Carry out the engine electronic diagnosis at the first starting after a long period of inactivity.
4. -Check the oil level conditions, and if necessary, top up or replace with synthetic oil FNM® SAE
5W40.
5. Verify the clogging level and if necessary replace the oil filter.
6. Check the coolant level and if necessary top up. Drain the sea water circuits.
7. Verify and if necessary replace or clean the fuel filter.
8. Clean the air filter.
®
FNM HPE Series
105
9. Verify the belts and tighteners status.
10. Verify the integrity of the sea water pump impeller.
11. Check the integrity of the anodes in order to provide a correct one.
12. Verify and if is necessary grease: the starter pinion, (with white grease for gears Bardahl®
Viscogrease), and the turbocharger actuator leverages.
13. Keep the engine on for some minutes then turn it off and check again the engine oil and
coolant levels.
14. Check for any leaks.
The engine is now ready to resume normal operation.
106
FNM® HPE Series
3.6 Other useful information for maintenance
3.6.1 Wiring and electrical parts
The ECU (Electronic Control Unit) BOX contains the electronic control unit of the engine, the electric
connections and relays, the red stop button, the Amphenol® plugs for the engine wiring, the fuses
indicator lights. The degree of protection of the box is IP 67 that prevents damage from dust and
splashing water.
Press the Red Stop Button in case of emergency and in every emergency condition that
could cause damage to persons!
Take care to disconnect the ECU box by pushing the stop button during long inactivity period, during
the battery replacement and during all operations on the engine.
It is advisable to let carry out any operation on the engine and in particular on the electrical
wiring by authorized personnel.
The ECU box is equipped with a LED indicators panel to indicate the fuses integrity status.
The fuses are on the connectors of the circuit in order to make the replacement procedure easier. In
order to replace the fuses, refer to the following table:
FNM® HPE Series
107
Fuse
Fuse F7
Fuse F8
Fuse F9
Fuse F11
Fuse F10
Fuse F4
Fuse F3
Fuse F5
Fuse F2
Fuse F1
108
Service
Fuel heating
Low pressure fuel pump
Glow plugs main relay
Pin 4 ECU
Pin 5 ECU
Key-on
EOBD Diagnosis
Main relay
Not Used
Not Used
FNM® HPE Series
3.7 Specifications of your engine
HPE/P
HPE/P
40/150/150JD/170/
100/225/225JD/
170JD/190/190JD
250/250JD/250H
HPEL 65/90
4
4
5
1248
1910
2387
69,6
82,0
82,0
82,0
90,4
90,4
Four stroke diesel engine 17,6:1
18:1
Direct Common Rail Injection
Turbine with cooled
Turbine with variable geometry
turbocarter
16-Valve DOHC
20-Valve DOHC
1-3-4-2
1-2-4-5-3
800-850
800
750-800
HPE 40S/80/80SD
/110/110JD
HPEL 80
Cylinders
Displacement [cm3]
Bore [mm]
Stroke
Engine type
Compression ratio
Injection Type
Boosting
Timing system
Firing order
Idle speed [rpm]
Max revolution speed
(with load) [rpm]
FNM® HPE Series
4000-4200
4000
4200
HPE/P 300
HPEL 45
4
2988
95,8
104,0
4
1248
69,6
82,0
17,6:1
Turbine with cooled
none
body
16-Valve DOHC
1-3-4-2
750-850
800-850
4000-4200
4000-4200
109
HPE 40S/80/80SD
/110/110JD
HPEL 80
Maximum power [kW
@ rpm]
80,8 @ 4000-4400 (HPE
110/110JD)
58,8 @ 4000 (HPE 80)
55,1 @ 3800 (HPE 80SD)
66 @ 4000 (HPEL 80)
Maximum torque [Nm
@ rpm]
230 @ 2600 (HPE 110/110JD)
157 @ 2200 (HPE 80/80SD)
66 @ 4000 (HPEL 80)
Alternator
Engine oil capacity
(without filter) [l]
110
29,4 @ 3200 (HPE/P 40)
110 @ 4000 (HPE/P
150/150JD)
125 @ 4000 (HPE/P
170/170JD)
140 @ 4000 (HPE/P
190/190JD)
47,8 @ 4000 (HPEL 65)
66 @ 4000 (HPEL 90)
91.4 @ 2600 (HPE/P 40)
@ 2600 (HPE/P
150/150JD)
338 @ 2200 (HPE/P
170/170JD)
372 @ 2400 (HPE/P
190/190JD)
HPE/P
100/225/225JD/
250/250JD/250H
HPE/P 300
HPEL 45
184 @ 4200
(HPE/P250/250JD)
80,8 @ 3000 (HPE/P250H)
165 @ 4000
(HPE/P225/225JD)
217 @ 4000
33 @ 3000
460 @ 2600
(HPE250/250JD)
416 @ 2500
(HPE225/225JD)
560 @ 2600
-
75A 12V
105A 12V
140A 12V
110A 12V
75A 12V
3,2
4,0
4,5
7,5
3,2
8,5
65°C±1,5°C
80°C ±1,5°C
14,0
Thermostatic valve
Cooling capacity [l]
Sea water pump flow
[l/min]
Engine starter
Wet weight (excluding
transmission) [kg]
HPE/P
40/150/150JD/170/
170JD/190/190JD
HPEL 65/90
65°C±1,5°C
7,5
7,5
90 (24,0 gal/min)
100 (26,6 gal/min)
1,3 kW 12V
188
1,8 kW 12V
240
295
65°C±1,5°C
7,5
90 (24,0 gal/min)
2,6 kW 12V
1,3 kW 12V
335
150
FNM® HPE Series
3.7.1 Specifications of transmissions
The FNM marine engine is generally coupled to high reliability transmission systems. For the use and
maintenance of transmissions, please refer to the manufacturer's manual.
In the following table you will find the specifications of the transmission oil, as reported by the
individual producers:
Producer
ZF
Technodrive
Mercruiser
Transmission
model
ZF 45
ZF 45-1
ZF 63-A
ZF 63
ZF 63-IV
TM 345
TM 345-A
TM 485-A
TM 880-A
Seaprop 60
Bravo I
Bravo II
Bravo III
FNM® HPE Series
Oil Type
ATF
SAE 20W40
SAE 20W40
SAE 15W40
SAE 20W40
ATF
Quicksilver®
High
performance
Gear Lube*
Oil Capacity (liters, excluded
exchangers)
2,5
3,0
4,0
3,6
3,8
1,6 (with standard exchanger)
2,6
3,7
3,0
See the producer’s manual.
111
*: The one specified is gear oil. For all other fluids using the stern drive always consult the producer’s
manual.
For transmissions that are not listed, consult the data provided by the respective producer.
112
FNM® HPE Series
3.7.2 Meaning of the indicators on the analog panel
The engine control panel has a number of indicators and indicator lights to monitor the operation. If
one of these should turn on, see the table below for an explanation of the meaning.
Indicator or light
Oil pressure
indicator
Crankshaft
revolutions
counter
Engine coolant
temperature
Status
Needle included between 1
and 6 bar
Needle below 1 bar
Around 800 revolutions per
minute
Above 800 rpm
Between 75°C and 90°C
Above 90 ° C
Between 12V and 16V
Voltmeter
Alternator
FNM® HPE Series
Below 12V
Lit, engine off
Meaning
Indicates the normal engine oil pressure.
Involves a loss of engine oil or an insufficient amount of engine oil. The
"Low Oil Pressure" indicator light turns on together to the alarm buzzer of
the panel. Turn off the engine immediately and check the oil level.
Indicates the operation of the engine idle speed, i.e. when the gear is not
inserted.
Indicates the normal operation of the engine with gear engaged.
Indicates the temperature of normal engine operation.
Indicates an operating temperature too high. If the needle remains above
90 ° C for a long time the "Coolant high temperature" indicator light
turns on with the alarm buzzer of the panel. Reduce the engine speed
and if necessary stop the engine.
Indicates the voltage of the battery for the engine normal operation.
Indicates that the voltage is not enough for the proper functioning of all
electrical services. At the restart, the battery may not have the necessary
voltage to start the engine. During operation, the alternator indicator light
may turn on.
It is a condition of normal operation.
113
Indicator or light
indicator light
Status
Lit, indicates running engine
Glow plugs
indicator light
Lit, engine off
Blinking
Off
Low oil pressure
indicator light
On
Off
High coolant
temperature
indicator light
Generic failure
114
On
Off
Meaning
Indicates no recharge of the battery by the alternator. Turn off the engine
and check the belts status. If the belts are in good condition, the
malfunction may depend on the regulator of the alternator or the
alternator itself. Contact a FNM® service point.
It indicates the glow plugs preheating required to properly start the
engine.
Indicates a critical engine failure. Contact a FNM® service point to make
the diagnosis.
Indicates the normal operation of the engine.
Indicates low engine oil pressure. At the same time the alarm buzzer of
the panel turns on.
Turn off the engine immediately, because the lubrication system is
unable to work properly. Check the engine oil level and the erroneous
connection of the sensor to the electrical wiring.
Indicates the normal engine operation.
Indicates an engine overheating. At the same time the alarm buzzer of
the panel turns on. Turn off the engine immediately and check if the sea
water filter is clogged, the sea water valve is opened and the coolant is
sufficient. Also check the cooling system and any losses, verify that the
impeller sea water pump is in good condition: Bleed air from the cooling
system and check the connection of the sensor to the electrical wiring.
Indicates normal operation
FNM® HPE Series
Indicator or light
indicator light
Status
On
Off
Water in fuel
indicator light
On
Off
Transmission oil
anomaly indicator
light
On, stern drive or gearbox
installations
On, saildrive installations
FNM® HPE Series
Meaning
The reason for which the indicator light turns on can be:
- Problem on injection system
- ECU malfunction
- Engine over heating
The FNM® authorized service point must make an immediate diagnosis.
Indicates normal operation
The indicator light may turn on for:
- Water presence in the fuel filter
- Malfunction of the water in fuel sensor
Check and drain the fuel filter. If the problem persists, make a diagnosis
by an authorized FNM® service point.
Indicates normal operation
Indicates the low level of oil in the transmission. Check and fill the
transmission system with proper lubricant, then turn on the engine
again. If the problem persists, contact an authorized FNM ® service
point.
Indicates leakage of seawater from the saildrive seals. Check the seal
status.
115
3.7.3 Meaning of the indicators on the digital panel
If the installation includes a digital instrument panel, consult this table to interpret the information that
the system can display.
Display views
Crankshaft
revolutions
counter
Status
Needle around 800 rounds
per minute
Needle between 800 and
4500 revolutions per minute
Needle over 4500 revolutions
per minute
Between 12V and 15V
Volts
Below 12V
Above 15V
Trim
Oil press
116
From 0 to 8 units
Value between 0.7 and 6 bar
Meaning
Indicates the operation of the engine idle speed, i.e. when the gear is not
inserted.
Indicates the normal operation of the engine with gear engaged.
Indicates a too high regime of operation.
The "Rev Limit Exceeded Critical" indicator light turns on together with
the alarm buzzer of the panel.
Lower the position of the throttle to bring it up gradually to 0 and turn
off the engine. If the engine does not turn off, act on the emergency red
button located on the control box.
Indicates the voltage of the battery for the engine normal operation.
Indicates that the voltage is not enough for the proper functioning of all
electrical services. At the restart, the battery may not have the necessary
voltage to start the engine. During operation, the “Low System Voltage
Amber Warning” alarm turns on " with the buzzer and the warning lights.
Indicates excessive voltage to the battery, which can lead to electrical
short circuits. The "High Voltage Warning System" alarm turns on with
the buzzer and the warning lights. Turn off the engine immediately.
Indicates the position relative to the Trim inclination angle.
Indicates the engine oil normal pressure.
FNM® HPE Series
Display views
Status
Value below 0.7 bar
Engine Hour
Over 0h
Fuel Level
From 0 to 8 units
Water Press
Fuel Left
Fuel Used
Fuel Inst
Greater than 0 bar
Greater than 0 litres
Greater than 0 litres
Greater than 0 liters/hour
Forward
Neutral
Reverse
From 60 to 150°C
From 0 to 40 bar
Between 0 and 3 bar
Trans Gear
Trans Temp
Trans Press
Boost Press
Throttle or
Engine Load
Coolant Temp
FNM® HPE Series
Between 0 and 100%
Between 75°C and 90°C
Meaning
Involves a loss of engine oil or an insufficient amount of engine oil. The
"Low Oil Pressure" alarm Turns on with the buzzer and the warning
lights. Turn off the engine immediately and check the oil level.
Indicates the total number of hours of use that has the engine since it
was first turned on.
Indicates the amount of fuel still in the tank. Each unit represents 1 / 8 of
the fuel maximum volume that can be contained.
Indicates the engine coolant pressure.
Indicates the amount of fuel still available in the tank.
Indicates the amount of fuel used since last reset.
Indicates the engine fuel time consumption in liters per hour.
Indicates the forward gear engaged.
Indicates the neutral position.
Indicates reverse gear engaged.
Indicates the oil temperature inside the transmission.
Indicates the oil pressure inside the transmission.
Indicates the operating pressure of the turbocharger.
Indicate the percentage corresponding to the position of the throttle
relative to the engine acceleration.
Indicates the temperature of normal engine operation.
117
Display views
Status
Above 90 ° C
Glow plugs
indicator light (if
present)
Lit, engine off
Blinking
Off
Transmission oil
anomaly indicator
light
On, stern drive or gearbox
installations
On, Saildrive installations
Alarm:
CHECK ENGINE!
Displayed
Alarm:
ENGINE
EMERGENCY
STOP!
Displayed
118
Meaning
Indicates an operating temperature too high. If the needle remains above
90 ° C for a long time the "High Engine Temp! Critical” alarm turns on
together with the buzzer and the warning lights. Turn off the engine
immediately and check the coolant level.
It indicates the glow plugs preheating required to properly start the
engine.
Indicates a critical engine failure. Contact a FNM® service point to make
the diagnosis.
Indicates normal operation
Indicates the low level of oil in the transmission. Check and fill the
transmission system with proper lubricant, then start the engine again. If
the problem persists, contact an authorized FNM® service point.
Indicates leakage of seawater from the Saildrive seals. Check the seal
status.
Indicates a failure of the engine. At the same time the alarm buzzer of
the panel turns on. The reason for which the indicator light turns on can
be:
- Problem on injection system
- ECU malfunction
- Engine over heating
Make a diagnosis at a FNM® authorized service point.
Indicates a serious malfunction of the engine. At the same time the
alarm buzzer of the panel turns on.
Turn off the engine immediately and check it. Make a diagnosis at a
FNM® authorized service point.
FNM® HPE Series
Display views
Status
Alarm:
LOW OIL
PRESSURE
CRITICAL
Displayed
Alarm:
HIGH VOLTAGE
SYSTEM Amber
Warning
Displayed
Alarm:
LOW SYSTEM
VOLTAGE Amber
Warning
Displayed, engine running
Displayed, engine off
FNM® HPE Series
Meaning
Indicates low engine oil pressure, less than 0.7 bar. At the same time
the alarm buzzer of the panel turns on.
Turn off the engine immediately, because the lubrication system is
unable to work properly. Check the engine oil level and the erroneous
connection of the sensor to the electrical wiring.
Indicates an excessive electrical voltage (above 15V) and a problem with
the battery or the alternator.
Turn off the engine immediately to prevent short circuits or electrical
overloads.
Make the engine be checked by an authorized FNM® service point.
Indicates a low voltage (less than 12V) and a problem with the battery or
the alternator.
When switching off the engine, it may fail to start.
The most common cause is due to the alternator not charging the
battery. Turn off the engine and check the belts status. If the belts are in
good condition, the malfunction may depend on the regulator of the
alternator or the alternator itself. Contact a FNM® service point.
Indicates a too low voltage (less than 10V) of the battery, likely resulting
in difficulty to restart the engine.
Contact an authorized FNM® service point to verify the electrical system
and engine.
119
Display views
Status
Alarm:
WATER IN FUEL
Maintenance
Required
Displayed
Alarm:
HIGH BOOST
PRESSURE
Displayed
Alarm:
REV LIMIT
EXCEEDED
CRITICAL
Displayed
Alarm:
HIGH ENGINE
TEMP! CRITICAL
Displayed
120
Meaning
Indicates an obstruction in the fuel filter. At the same time the alarm
buzzer of the panel turns on. The reason for which the indicator light
turns on can be:
- Water presence in the engine fuel filter.
- Malfunction of the water in fuel sensor
Check and drain the fuel filter. If the problem persists, make a diagnosis
by an authorized FNM® service point.
Indicates excessive pressure of the turbocharger to the engine (greater
than 3 bar). Lower the position of the throttle to bring it up gradually to 0
and turn off the engine. If the problem persists when turned on, keep low
RPM without accelerating excessively and make the engine be checked
by an authorized FNM® service point.
Indicates a rotation speed of the engine too high, higher than 4500 rpm.
Lower the position of the throttle to bring it up gradually to 0 and turn off
the engine. If the engine does not turn off, act on the emergency red
button located on the control box.
If the problem recurs, make the engine be checked by an authorized
FNM® service point.
Indicates overheating of the engine, above 100 ° C. At the same time the
alarm buzzer of the panel turns on. Turn off the engine immediately and
check if the sea water filter is clogged, the sea water valve is opened and
the coolant is sufficient. Also check the cooling system and any losses,
verify that the impeller of the sea water pump is in good condition: Bleed
air from the cooling system and check the connection of the sensor to
the electrical wiring.
FNM® HPE Series
3.7.4 Troubleshooting
In the following table you will find, divided by the issue, the list of possible faults that cause a
malfunction of your engine, complete with the action to be taken to resolve it.
Possible Fault
The starter will not crank
Control lever not in neutral.
The emergency stop button is pushed in (ECU Box) .
Faulty or discharged battery (too low voltage ) .
Fuses blown.
Loose or corroded connections in the starting circuit.
Starter relay is not operated due to too low voltage caused by
a very long intermediate cable from engine to control panel
Wrong engine electric ground connection
Faulty starter-switch or faulty starter-relay.
Faulty starter-motor or pinion does not engage.
Seized components.
Water in the cylinders.
FNM® HPE Series
Possible Remedy
Put operating lever in neutral
Release it.
Check / charge the battery and check the alternator and its
connections.
Replace.
Clean and tighten the connections.
Install an auxiliary starter relay.
Inspect / review
Check / replace.
Check / replace the starter-motor.
Repair.
Repair.
121
Possible Fault
Possible Remedy
If the engine spins but does not start, no smoke comes out from the exhaust
Fuel supply valve closed.
Open.
(Almost) empty fuel tank.
Fill the tank.
Air in fuel supply system.
Check and bleed.
Fuel filter clogged with water and/or contamination.
Check or replace.
Fuel pre-filter clogged .
Clean/replace
Fuses burnt.
Check/replace.
Leaking in the fuel supply line or fuel injection line
Check / replace.
Vent line of fuel supply tank clogged.
Check/clean.
Clogged exhaust.
Check .
Check the electrical connection, check the pump, clean or
Fuel low pressure electrical pump is not working.
replace.
Fuel electric pressure regulator clogged
Unclog / replace
Faulty ECU.
Diagnosis / replace.
If the engine spins but does not start, smoke comes out from the exhaust
Air in fuel supply system.
Check and bleed the air.
Intake air filter clogged .
Clean/replace
Wrong fuel quality or contaminated fuel.
Check fuel. Drain and flush fuel tank. Replace with new fuel.
Faulty glow plugs.
Check / replace.
Incorrect lube oil SAE class or quality for ambient
Replace.
temperature.
122
FNM® HPE Series
Possible Fault
If the engine starts but runs unevenly or stops
(Almost) empty fuel tank.
Wrong fuel quality or contaminated fuel.
Clogged fuel supply line .
Vent line of fuel supply tank clogged.
Air in fuel supply system.
Fuel filter clogged with water and/or contamination.
Leaking in the fuel supply line or fuel injection line
Low battery voltage
Fuel high pressure line regulator fault
Faulty fuel injection injectors/pump.
Clogged exhaust.
FNM® HPE Series
Possible Remedy
Fill the tank.
Check fuel. Drain and flush fuel tank. Replace with new fuel.
Check/clean.
Check/clean.
Check and bleed.
Check or replace.
Check / replace.
Recharge/ replace
Replace
Check, replace if required.
Check .
123
Possible Fault
If the engine does not reach maximum rpm under load
Engine overloaded.
Dirty hull/propeller
Insufficient comburent air.
Air in fuel supply system.
Fuel filter clogged with water and/or contamination.
Fuel pre filter clogged
Leaking in the fuel supply line or fuel injection line
Incorrect lube oil SAE class or quality for ambient
temperature.
Wrong fuel quality or contaminated fuel.
Oil level too high.
Leak in the air manifold. Dirty intercooler.
Clogged exhaust.
Damaged turbocharger
Dirty injectors
Transmission.
124
Possible Remedy
Check the propeller size /incorrect propeller
Clean
Check .
Check and bleed.
Check or replace.
Clean /replace.
Check / replace.
Replace.
Check fuel. Drain and flush fuel tank. Replace with new fuel.
Reduce the level.
Check /replace and clean
Check/clean.
Replace.
Check, replace if required.
Check.
FNM® HPE Series
Possible Fault
If the engine overheats excessively
Seacock closed
Leaks in the sea water suction system.
Sea water filter clogged.
Sea water impeller damaged
Coolant level too low
Leaks in the coolant circuit.
Heat exchanger damaged or clogged by rubber parts of the
damaged impeller.
Oil level too high.
Oil level too low.
Insufficient comburent air.
Engine becomes apparently overheated as a result of faulty
temperature switch, sensor or meter.
Faulty thermostat .
Faulty coolant pump
Faulty oil filter/dirty oil exchanger.
Faulty turbo compressor.
If not all cylinders are working
Air in fuel supply system.
Fuel filter clogged with water and/or contamination.
Leaking in the fuel supply line or fuel injection line
Faulty injectors.
Locked suction valves.
FNM® HPE Series
Possible Remedy
Open.
Check / replace.
Check/clean.
Check / replace.
Check / fill up.
Check .
Check/clean.
Reduce the level.
Raise the level.
Check/clean the filter.
Check / replace.
Check / replace.
Check/clean.
Replace.
Check /replace
Check and bleed.
Check or replace.
Check / replace.
Check, replace if required.
Check, replace if required.
125
Possible Fault
If the oil pressure is low
Oil level too low.
Excessive inclination of engine.
Oil pressure apparently too low due to faulty oil pressure
switch, sensor or meter.
Incorrect lube oil SAE class or quality for ambient
temperature.
Oil leaks .
Clogged oil filter
Faulty oil pump
If the oil consumption is excessive
Oil level too high.
Excessive inclination of engine.
Insufficient comburent air.
Incorrect lube oil SAE class or quality for ambient
temperature.
Engine overloaded.
Leak in lubricating oil system.
Oil steams condenser clogged .
Turbocharger oil leaks .
126
Possible Remedy
Raise the level.
Check / Adjust.
Check /replace
Replace.
Check /replace
Replace.
Repair / replace.
Reduce the level.
Check / Adjust.
Check .
Replace.
Check size of propeller.
Repair / replace.
Replace
Replace or repair.
FNM® HPE Series
Possible Fault
If the fuel consumption is excessive
Incorrect fuel quality or dirty fuel.
Insufficient comburent air.
Fuel leaks .
Faulty injector/injector pump.
If black smoke comes out of the exhaust (idling)
Oil level too high.
Excessive inclination of engine.
Faulty injectors/sprayers.
If blue smoke comes out of the exhaust (idling)
Oil level too high.
Leaking from turbo compressor oil seal.
If black smoke comes out of the exhaust (full load)
Insufficient intake air, dirty air filter.
Leak in the air manifold.
Dirty intercooler.
Incorrect oil level .
Engine overloaded, max. rpm is not reached.
Engine overloaded, dirty propeller -boat hull. Excessive
weight on board.
Turbocharger actuator blocked
Faulty turbo compressor.
FNM® HPE Series
Possible Remedy
Check fuel. Drain and rinse fuel tank. Replace with new fuel.
Check .
Check and repair.
Check, replace if required.
Reduce the level.
Check / Adjust.
Check / replace.
Reduce the level.
Check /replace the seal
Check/clean.
Check / replace.
Check/clean.
Check.
Check sizes of propeller and/or boat weight.
Check and clean if required.
Unblock / replace.
Check / replace.
127
Possible Fault
If white smoke comes out of the exhaust (full load)
Air in fuel supply system.
Wrong fuel quality or contaminated fuel.
Water in fuel system.
Faulty glow plugs.
Faulty injector/injection pump.
Vapors condensing at the exhaust for very low ambient
temperature
If you find burnt oil traces at the exhaust.
Oil level too high .
Faulty turbocharger .
Excessive wear of cylinder / piston, piston rings.
128
Possible Remedy
Check and bleed.
Check fuel. Drain and flush fuel tank. Replace with new fuel.
Check water separator.
Check / replace.
Check, replace if required.
Check .
Check, Repair / Replace .
Check compression; refurbish engine.
FNM® HPE Series
3.7.5 Diagnosis
All HPE engines are equipped with a plug for electronic diagnosis connection. Make the diagnosis only
to an authorized FNM® service point.
FNM® HPE Series
129
4 Maintenance booklet
130
FNM® HPE Series
4.1 Engine Identification Data | Dati identificativi del motore
Thiss data is to be compiled by the dealer and is necessary to the customer to verify the engine
warranty. | Questi dati sono da compilare a cura del rivenditore e sono necessary al cliente per verificare la garanzia del
suo motore.
Engine type | Modello motore:
Engine serial number | Matricola motore:
Transmission type | Modello trasmissione:
Transmission serial number | Matricola trasmissione:
1st Owner Name | 1° Proprietario:
Sea trial date | Data test a mare:
Dealer stamp and signature | Timbro e firma del rivenditore:
FNM® HPE Series
131
4.2 Ordinary and Extraordinary Maintenance Register | Registro della manutenzione
periodica programmata e straordinaria
Maintenance |
Intervento
Hourmeter and Date
| Ore motore e Data
1st Service (30h) |
Primo tagliando
(30h)
Hourmeter | Ore:
______________
Date | Data:
______________
2nd Service |
Secondo tagliando
Hourmeter | Ore:
______________
Date | Data:
______________
Ordinary |
Ordinario (100h)
Advanced |
Avanzato (800h)
3rd service | Terzo
tagliando
Hourmeter | Ore:
______________
Date | Data:
______________
Ordinary |
Ordinario (100h)
Advanced |
Avanzato (800h)
132
Notes | Note
Type | Tipo
Assistance Center
Stamp and Signature
| Firma e Timbro del
Centro Assistenza
30h
FNM® HPE Series
Maintenance |
Intervento
Hourmeter and Date
| Ore motore e Data
4th service | Quarto
tagliando
Hourmeter | Ore:
______________
Date | Data:
______________
Ordinary |
Ordinario (100h)
Advanced |
Avanzato (800h)
5th service | Quinto
tagliando
Hourmeter | Ore:
______________
Date | Data:
______________
Ordinary |
Ordinario (100h)
Advanced |
Avanzato (800h)
6th service | Sesto
tagliando
Hourmeter | Ore:
______________
Date | Data:
______________
Ordinary |
Ordinario (100h)
Advanced |
Avanzato (800h)
7th service |
Settimo tagliando
Hourmeter | Ore:
______________
Date | Data:
______________
Ordinary |
Ordinario (100h)
Advanced |
Avanzato (800h)
FNM® HPE Series
Notes | Note
Type | Tipo
Assistance Center
Stamp and Signature
| Firma e Timbro del
Centro Assistenza
133
Maintenance |
Intervento
Hourmeter and Date
| Ore motore e Data
8th service | Ottavo
tagliando
Hourmeter | Ore:
______________
Date | Data:
______________
Ordinary |
Ordinario (100h)
Advanced |
Avanzato (800h)
9th service | Nono
tagliando
Hourmeter | Ore:
______________
Date | Data:
______________
Ordinary |
Ordinario (100h)
Advanced |
Avanzato (800h)
10th service |
Decimo tagliando
Hourmeter | Ore:
______________
Date | Data:
______________
Ordinary |
Ordinario (100h)
Advanced |
Avanzato (800h)
11th service |
Undicesimo
tagliando
Hourmeter | Ore:
______________
Date | Data:
______________
Ordinary |
Ordinario (100h)
Advanced |
Avanzato (800h)
134
Notes | Note
Type | Tipo
Assistance Center
Stamp and Signature
| Firma e Timbro del
Centro Assistenza
FNM® HPE Series
Maintenance |
Intervento
Hourmeter and Date
| Ore motore e Data
12th service |
Dodicesimo
tagliando
Hourmeter | Ore:
______________
Date | Data:
______________
Ordinary |
Ordinario (100h)
Advanced |
Avanzato (800h)
13th service |
Tredicesimo
tagliando
Hourmeter | Ore:
______________
Date | Data:
______________
Ordinary |
Ordinario (100h)
Advanced |
Avanzato (800h)
14th service |
Quattordicesimo
tagliando
Hourmeter | Ore:
______________
Date | Data:
______________
Ordinary |
Ordinario (100h)
Advanced |
Avanzato (800h)
15th service |
Quindicesimo
tagliando
Hourmeter | Ore:
______________
Date | Data:
______________
Ordinary |
Ordinario (100h)
Advanced |
Avanzato (800h)
FNM® HPE Series
Notes | Note
Type | Tipo
Assistance Center
Stamp and Signature
| Firma e Timbro del
Centro Assistenza
135
Hourmeter and Date
| Ore motore e Data
Notes | Note
Type | Tipo
Assistance Center
Stamp and Signature
| Firma e Timbro del
Centro Assistenza
Hourmeter | Ore:
______________
Date | Data:
______________
Hourmeter | Ore:
______________
Date | Data:
______________
Hourmeter | Ore:
______________
Date | Data:
______________
Hourmeter | Ore:
______________
Date | Data:
______________
136
FNM® HPE Series
Copy this page and attach it to this book for additional maintenance operations | Fotocopi questa pagina e la alleghi al libretto per interventi aggiuntivi operations.
Maintenance |
Intervento
Notes:
FNM® HPE Series
137
Notes:
138
FNM® HPE Series
Notes:
FNM® HPE Series
139
Notes:
140
FNM® HPE Series
Document 6.045.320.1 – HPE Series Owner’s Manual – ENG Language
Release
Update
0
First release
1
Added Glow Plug signaling at the pages 27, 28 and 29
FNM® HPE Series
Date
21/03/2012
31/05/2012
141
To obtain service:
FNM Service
C.M.D. Costruzioni Motori Diesel S.p.A.
Nucleo Industriale Valle di Vitalba
85020 – Italia
Tel. +39 0972 715757 – int. 183
Fax. +39 0972 715696
Email: [email protected]
Web: www.fnm-marine.com
Printed in Italy
Order code 6.045.320.1 – Rev. 1 dated 31/05/2012
© CMD S.p.A. All rights reserved.
FNM® is a registered trademark of C.M.D. – Costruzioni Motori Diesel S.p.A.